2002 JEEP GRAND CHEROKEE Time set

and therefore creates pressure in the pump. The tun-
ing of the front and rear axle orifices and valves
inside the gerotor pump is unique and each system
includes a torque-limiting pressure relief valve to
protect the clutch pack, which also facilitates vehicle
control under extreme side-to-side traction varia-
tions. The resulting pressure is applied to the clutch
pack and the transfer of torque is completed.
Under conditions in which opposite wheels are on
surfaces with widely different friction characteristics,
Vari-loktdelivers far more torque to the wheel on
the higher traction surface than do conventional
Trac-loktsystems. Because conventional Trac-lokt
differentials are initially pre-loaded to assure torque
transfer, normal driving (where inner and outer
wheel speeds differ during cornering, etc.) produces
torque transfer during even slight side-to-side speed
variations. Since these devices rely on friction from
this preload to transfer torque, normal use tends to
cause wear that reduces the ability of the differential
to transfer torque over time. By design, the Vari-lokt
system is less subject to wear, remaining more con-
sistent over time in its ability to transfer torque. The
coupling assembly is serviced as a unit. From a ser-
vice standpoint the coupling also benefits from using
the same lubricant supply as the ring and pinion
gears.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, tooth contact, worn/damaged
gears, or the carrier housing not having the proper
offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side±gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
3 - 92 REAR AXLE - 226RBAWJ
REAR AXLE - 226RBA (Continued)

(14) Remove differential case and dummy bearings
from the housing.
(15) Install the pinion gear in the housing. Install
the pinion yoke and establish the correct pinion
rotating torque.
(16) Install differential case and Dummy Bearings
6929-A in the housing.
(17) Install a single dummy shim in the ring gear
side. Install bearing caps and tighten bolts snug.
(18) Seat ring gear side dummy bearing (Fig. 16).
(19) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads. (Fig. 17).
(20) Push and hold differential case toward pinion
gear and zero dial indicator (Fig. 20).
(21) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 21). Add Dummy Shim thickness to this read-
ing. This will be the total shim thickness to achieve
zero backlash.
(22) Subtract 0.152 mm (0.006 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. This total is the thickness
shim required to achieve proper backlash.(23) Subtract backlash shim thickness from the
total preload shim thickness. The remainder is the
shim thickness required on the pinion side of the
housing.
(24) Rotate dial indicator out of the way on pilot
stud.
(25) Remove differential case and dummy bearings
from the housing.
(26) Install side bearings and cups on differential
case.
(27) Install spreader W-129-B, utilizing some items
from Adapter Set 6987, on the housing and spread
axle opening enough to receive differential case.
(28) Place the bearing preload shims in the hous-
ing against the axle tubes.
(29) Install differential case into the housing.
(30) Remove spreader from housing.
(31) Rotate the differential case several times to
seat the side bearings.
Fig. 20 ZERO DIAL INDICATOR
1 - DIAL INDICATOR FACE
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - HOUSING
5 - DIFFERENTIAL CASE
Fig. 21 DIFFERENTIAL CASE RING GEAR SIDE
1 - READ DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
3 - 102 REAR AXLE - 226RBAWJ
REAR AXLE - 226RBA (Continued)

NOTE: The front outer brake shoes are equipped
with a wear indicator. The indicator will produce an
audible noise when it contacts the rotor surface.
BRAKE CHATTER
Brake chatter is usually caused by loose or worn
components, or glazed/burnt lining. Rotors with hard
spots can also contribute to chatter. Additional causes
of chatter are out-of-tolerance rotors, brake lining not
securely attached to the shoes, loose wheel bearings
and contaminated brake lining.
THUMP/CLUNK NOISE
Thumping or clunk noises during braking are fre-
quentlynotcaused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components.
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING
Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at
all times.
Do not pump the brake pedal at any time while
bleeding. Air in the system will be compressed into
small bubbles that are distributed throughout the
hydraulic system. This will make additional bleeding
operations necessary.
Do not allow the master cylinder to run out of fluid
during bleed operations. An empty cylinder will allow
additional air to be drawn into the system. Check the
cylinder fluid level frequently and add fluid as
needed.
Bleed only one brake component at a time in the
following sequence:
(1) Fill the master cylinder reservoir with brake
fluid.
(2) If calipers are overhauled, open all caliper
bleed screws. Then close each bleed screw as fluid
starts to drip from it. Top off master cylinder reser-
voir once more before proceeding.
(3) Attach one end of bleed hose to bleed screw
and insert opposite end in glass container partially
filled with brake fluid (Fig. 1). Be sure end of bleed
hose is immersed in fluid.
(4) Open up bleeder, then have a helper press
down the brake pedal. Once the pedal is down close
the bleeder. Repeat bleeding until fluid stream is
clear and free of bubbles. Then move to the next
wheel.
STANDARD PROCEDURE - PRESSURE
BLEEDING
Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at
all times.
Do not pump the brake pedal at any time while
bleeding. Air in the system will be compressed into
small bubbles that are distributed throughout the
hydraulic system. This will make additional bleeding
operations necessary.
Do not allow the master cylinder to run out of fluid
during bleed operations. An empty cylinder will allow
additional air to be drawn into the system. Check the
cylinder fluid level frequently and add fluid as
needed.
Bleed only one brake component at a time in the
following sequence:
Follow the manufacturers instructions carefully
when using pressure equipment. Do not exceed the
tank manufacturers pressure recommendations. Gen-
erally, a tank pressure of 51-67 kPa (15-20 psi) is suf-
ficient for bleeding.
Fill the bleeder tank with recommended fluid and
purge air from the tank lines before bleeding.
Do not pressure bleed without a proper master cyl-
inder adapter. The wrong adapter can lead to leak-
age, or drawing air back into the system. Use
adapter provided with the equipment or Adapter
6921.
Fig. 1 Bleed Hose Setup
1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
WJBRAKES - BASE 5 - 5
BRAKES - BASE (Continued)

tions also allows the driver to set steering wheel tilt
and seat position to the most comfortable position.
The position of the brake and accelerator pedals can
be adjusted without compromising safety or comfort
in actuating the pedals. Repositioning the pedals
does not change the effort required for actuation.
Change of pedal position is accomplished by means
of a motor driven screw. Operating the adjustable
pedal switch activates the pedal drive motor. The
pedal drive motor turns a screw that changes the
position of the brake and accelerator pedals. The
pedal can be moved rearward (closer to the driver) or
forward (away from driver). The brake pedal is
moved on its drive screw to a position where the
driver feels most comfortable (Fig. 52).
The accelerator pedal is moved at the same time
and the same distance as the brake pedal. The accel-
erator pedal adjustment screw is turned by a flexible
shaft slaved off the brake adjustment screw.
Neither the pedal drive motor nor drive mecha-
nism are subject to the mechanical stress of brake or
accelerator application.
²SYSTEM FEATURES:
²Range of Adjustment: The pedals may be
adjusted up to 3 in. (75 mm)
²Pedal Adjustment Speed: 0.5 in./sec (12.5
mm/sec)
²Pedal Adjustment Inhibitors: Pedal adjust-
ment is inhibited when the vehicle is in reverse or
when cruise control is activated.
²Memory: An optional memory feature is avail-
able. This allows storing of one or two preferred
pedal positions in the Adjustable Pedal Module
(APM). A preferred position can be stored and
recalled using the door-mounted switches. A stored
pedal position can be recalled (but not stored)
using the Remote Keyless Entry (RKE).
²
Adjustable Pedal Feedback Message: The Elec-
tronic Vehicle Information Center (EVIC) will display
a message when the APS is disabled. ie:9Adjustable
Pedal Disabled - Cruise Control Engaged9or9Adjust-
able Pedal Disabled - Vehicle in Reverse9.
²Damage Prevention: Foot pressure or debris
can stall pedal adjustment. In order to avoid dam-
age to system components during pedal adjust-
ment, the APM will monitor pedal position sensor
voltage. If the APM does not detect expected volt-
age change within 1.5 seconds, it will cut power to
the adjustable pedal motor.
OPERATION
The brake pedal is attached to the booster push
rod. When the pedal is depressed, the primary
booster push rod is depressed which moves the
booster secondary rod. The booster secondary rod
depresses the master cylinder piston.
REMOVAL
REMOVAL - NON-ADJUSTABLE PEDAL
(1) Remove retainer clip that holds booster to
pedal pin (Fig. 53).
Fig. 52 ADJUSTABLE PEDALS ASSEMBLY
1 - HARNESS
2 - ADJUSTABLE PEDAL BRACKET
3 - CABLE
4 - ACCELERATOR PEDAL
5 - BRAKE PEDAL
6 - ADJUSTABLE PEDAL MOTOR
7 - BRAKE LIGHT SWITCH
8 - ADJUSTABLE PEDALS MODULE
Fig. 53 Push Rod Retainer Clip
1 - RETAINER CLIP
2 - PUSH ROD
3 - PEDAL PIN
5 - 26 BRAKES - BASEWJ
PEDAL (Continued)

INSTALLATION
INSTALLATION - FRONT DISC BRAKE ROTOR
NOTE: If a new rotor is installed it must be match
mounted to the hub/bearing.
(1) Install rotor on hub studs in its original loca-
tion.
(2) Install the caliper anchor assembly on the
knuckle. Install anchor bolts and tighten to 90-115
N´m (66-85 ft. lbs.).
(3) Install wheel and tire assembly.
(4) Remove support and lower the vehicle.
(5) Pump brake pedal to seat caliper pistons and
brake shoes. Do not move vehicle until firm brake
pedal is obtained.
INSTALLATION - REAR DISC BRAKE ROTOR
(1) Install rotor on axle studs.
(2) Install the caliper anchor assembly.
(3) Install anchor bolts and tighten to 90-115 N´m
(66-85 ft. lbs.).
(4) Install wheel and tire assembly.
(5) Remove support and lower the vehicle.
(6) Pump brake pedal until caliper pistons and
brake shoes are seated.
PARKING BRAKE
OPERATION
The parking brakes operated by a automatic ten-
sioner mechanism built into the hand lever and cable
system. The front cable is connected to the hand
lever and the equalizer. The rear cables attached to
the equalizer and the parking brake shoe actuator.
A set of drum type brake shoes are used for park-
ing brakes. The shoes are mounted to the rear disc
brake adaptor. The parking brake drum is integrated
into the rear disc brake rotor.
Parking brake cable adjustment is controlled by an
automatic tensioner mechanism. The only adjust-
ment if necessary is to the park brake shoes if the
linings are worn.
DIAGNOSIS AND TESTING - PARKING BRAKE
NOTE: Parking brake adjustment is controlled by an
automatic cable tensioner and does not require
adjustment. The only adjustment that may be nec-
essary would be to the park brake shoes if they are
worn.
The parking brake switch is in circuit with the red
warning lamp in the dash. The switch will cause the
lamp to illuminate only when the parking brakes are
applied. If the lamp remains on after parking brake
release, the switch or wires are faulty.
If the red lamp comes on a fault has occurred in
the front or rear brake hydraulic system.
If the red warning lamp and yellow warning lamp
come on, the electronic brake distribution may be at
fault.
In most cases, the actual cause of an improperly
functioning parking brake (too loose/too tight/won't
hold), can be traced to a parking brake component.
NOTE: The leading cause of improper parking brake
operation, is excessive clearance between the park-
ing brake shoes and the shoe braking surface.
Excessive clearance is a result of lining and/or
drum wear, drum surface machined oversize.
Excessive parking brake lever travel (sometimes
described as a loose lever or too loose condition), is
the result of worn brake shoes, improper brake shoe
adjustment, or improperly assembled brake parts.
A too loose condition can also be caused by inoper-
ative or improperly assembled parking brake shoe
parts.
A condition where the parking brakes do not hold,
will most probably be due to a wheel brake compo-
nent.
Items to look for when diagnosing a parking brake
problem, are:
²Brake shoe wear
²Drum surface (in rear rotor) machined oversize
²Front cable not secured to lever
²Rear cable not attached to actuator
²Rear cable seized
²Parking brake lever not seated
²Parking brake lever bind
5 - 34 BRAKES - BASEWJ
ROTORS (Continued)

DIAGNOSIS AND TESTING - ANTILOCK
BRAKES
The ABS brake system performs several self-tests
every time the ignition switch is turned on and the
vehicle is driven. The CAB monitors the systems
input and output circuits to verify the system is oper-
ating correctly. If the on board diagnostic system
senses that a circuit is malfunctioning the system
will set a trouble code in its memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Electrical section. For test proce-
dures refer to the Chassis Diagnostic Manual.
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM
ABS system bleeding requires conventional bleed-
ing methods plus use of the DRB scan tool. The pro-cedure involves performing a base brake bleeding,
followed by use of the scan tool to cycle and bleed the
HCU pump and solenoids. A second base brake bleed-
ing procedure is then required to remove any air
remaining in the system.
(1) Perform base brake bleeding. (Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(2) Connect scan tool to the Data Link Connector.
(3) Select ANTILOCK BRAKES, followed by MIS-
CELLANEOUS, then ABS BRAKES. Follow the
instructions displayed. When scan tool displays TEST
COMPLETE, disconnect scan tool and proceed.
(4) Perform base brake bleeding a second time.
(Refer to 5 - BRAKES - STANDARD PROCEDURE)
OR (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(5) Top off master cylinder fluid level and verify
proper brake operation before moving vehicle.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
G-Sensor Bolt 5.6 Ð 50
Hydraulic Control Unit/Controller
Antilock Brakes
Mounting Bolts12 9 125
Hydraulic Control Unit/Controller
Antilock Brakes
Brake Lines16 Ð 144
Hydraulic Control Unit/Controller
Antilock Brakes
CAB Screws1.8 Ð 16
Wheel Speed Sensors
Front Sensor Bolt12-14 106-124 Ð
Wheel Speed Sensors
Rear Sensor Bolt12-14 106-124 Ð
5 - 42 BRAKES - ABSWJ
BRAKES - ABS (Continued)

AUDIO
DESCRIPTION
An audio system is standard factory-installed
equipment on this model. The standard equipment
audio system includes an AM/FM/cassette (RBB sales
code) radio receiver, and speakers in six locations.
Several combinations of radio receivers and speaker
systems are offered as optional equipment on this
model. The audio system uses an ignition switched
control of battery current so that the system will only
operate when the ignition switch is in the On or
Accessory positions.
A Compact Disc (CD) changer with a ten disc mag-
azine, remote radio switches with six functions
mounted to the backs of the steering wheel spokes,
and a memory system that automatically stores and
recalls up to twenty radio station presets (ten AM
and ten FM) and the last station listened to for two
drivers are optional factory-installed equipment on
this model. Refer to Electrical, Power Seats for more
information on the memory system.
The audio system includes the following compo-
nents:
²Antenna
²Compact disc changer (available with RBP sales
code radio receivers only)
²Power amplifier (with premium speaker system
only)
²Radio noise suppression components
²Radio receiver
²Remote radio switches
²Speakers
Certain functions and features of the audio system
rely upon resources shared with other electronic
modules in the vehicle over the Programmable Com-
munications Interface (PCI) data bus network. The
PCI data bus network allows the sharing of sensor
information. This helps to reduce wire harness com-
plexity, internal controller hardware, and component
sensor current loads. At the same time, this system
provides increased reliability, enhanced diagnostics,
and allows the addition of many new feature capabil-
ities. For diagnosis of these electronic modules or of
the PCI data bus network, the use of a DRB scan
tool and the proper Diagnostic Procedures manual
are recommended.
The other electronic modules that may affect audio
system operation are as follows:
²Body Control Module (BCM)- (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/BODY CONTROL/CENTRAL TIMER MODUL
- DESCRIPTION) for more information.
²Driver Door Module (DDM)(Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-ULES/DRIVER DOOR MODULE - DESCRIPTION)
for more information.
²Passenger Door Module (PDM)(Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/DRIVER DOOR MODULE - DESCRIPTION)
for more information.
The audio system includes the following major
components, which are described in further detail
elsewhere in this service information:
²Amplifier- On models equipped with the
optional premium speaker system, an audio power
amplifier is located on the rear floor panel under-
neath the right end of the rear seat cushion in the
passenger compartment.
²Antenna Body and Cable- The most visible
component of the antenna body and cable are the
antenna adapter and the antenna cap nut, which are
located on the top of the right front fender panel of
the vehicle, near the right end of the cowl plenum.
²Antenna Mast- The antenna mast is a metal
rod that extends upward from the antenna body and
cable on the top of the right front fender panel of the
vehicle, near the right end of the cowl plenum.
²Radio- The radio for this model is located in
the instrument panel center stack area, inboard of
the instrument cluster and above the heater and air
conditioner controls.
²Radio Noise Suppression Ground Strap-A
radio noise suppression ground strap is installed
between the rear of the engine cylinder head(s) and
the dash panel sheet metal in the engine compart-
ment.
²Speaker- The standard speaker system
includes six speakers in six locations, while the pre-
mium speaker system includes an amplifier for the
six speakers in six locations.
Hard wired circuitry connects the audio system
components to each other through the electrical sys-
tem of the vehicle. These hard wired circuits are
integral to several wire harnesses, which are routed
throughout the vehicle and retained by many differ-
ent methods. These circuits may be connected to each
other, to the vehicle electrical system and to the
audio system components through the use of a com-
bination of soldered splices, splice block connectors
and many different types of wire harness terminal
connectors and insulators. Refer to the appropriate
wiring information in this service manual for com-
plete standard and premium audio system circuit
diagrams. The wiring information includes proper
wire and connector repair procedures, further details
on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices, and grounds.
8A - 2 AUDIOWJ

AUDIO SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO AUDIO 1. Fuse faulty. 1. Check radio fuse in Junction Block (JB) and
Ignition-Off Draw (IOD) fuse in Power Distribution
Center (PDC). Replace fuses, if required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector.
Repair, if required.
3. Wiring faulty. 3. Check for battery voltage at radio connector.
Repair wiring, if required.
4. Radio ground faulty. 4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
5. Radio faulty. 5. (Refer to 8 - ELECTRICAL/AUDIO/RADIO -
DIAGNOSIS AND TESTING).
6. Speakers faulty. 6. (Refer to 8 - ELECTRICAL/AUDIO/SPEAKER -
DIAGNOSIS AND TESTING).
7. Amplifier faulty (if
equipped).7. (Refer to 8 - ELECTRICAL/AUDIO/AMPLIFIER
- DIAGNOSIS AND TESTING).
NO RADIO DISPLAY 1. Fuse faulty. 1. Check radio fuse in Junction Block (JB) and
Ignition-Off Draw (IOD) fuse in Power Distribution
Center (PDC). Replace fuses, if required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector.
Repair, if required.
3. Wiring faulty. 3. Check for battery voltage at radio connector.
Repair wiring, if required.
4. Radio ground faulty. 4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
5. Radio faulty. 5. (Refer to 8 - ELECTRICAL/AUDIO/RADIO -
DIAGNOSIS AND TESTING).
CLOCK WILL NOT KEEP
SET TIME1. Fuse faulty. 1. Check Ignition-Off Draw (IOD) fuse in the
Power Distribution Center (PDC). Replace fuse, if
required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector.
Repair, if required.
3. Wiring faulty. 3. Check for battery voltage at radio connector.
Repair wiring, if required.
4. Radio ground faulty. 4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
5. Radio faulty. 5. (Refer to 8 - ELECTRICAL/AUDIO/RADIO -
DIAGNOSIS AND TESTING).
8A - 4 AUDIOWJ
AUDIO (Continued)