Here is the official TSB on the brake issues for 2000-2002 JGC's. We've done the recommended work and I haven't had a problem since - however, I do agree that Jeep needs to do something about this.
TSB 05-003-02B - FRONT BRAKE PULSATION DURING LIGHT TO MODERATE BRAKE APPLICATION
Date: 12/16/02 (supersedes 0500302A Dated June 10, 2002)
Model Year (s) : 1999-2002 (WJ models built through May 10, 2002)
Description: Brake roughness or pedal pulsation when the brakes are applied. The customer may experience a vibration of the steering wheel, floor, seat, instrument panel, or a minor pedal pulsation (brake roughness) under light to moderate pedal application. The condition may be caused by excessive thickness variation of the brake rotor surface.
Details: This bulletin involves the replacement of both front brake rotors and caliper assemblies. NOTE: NEW BRAKE ROTORS MUST BE USED WITH THE NEW BRAKE CALIPERS.
Diagnosis:
1. Determine if the front brake vibration/pulsation is caused by excessive thickness variation of either front brake rotor.
2. If excessive thickness variation of the front brake rotor is at fault perform the Repair Procedure.
3. If this bulletin has already been performed, and front brake pulsation/vibration is present, do not perform the Repair Procedure. Investigate other possible cases for front brake pulsation/vibration.
Parts required:
52098672 Rotor (MSRP: $65.10 ea.)
05093174AA Caliper kit (Left & Right calipers, brake pads, attachment bolts, banjo sealing washers)
04318080AB Brake fluid (DOT3/MS-4574)
TSB addendum.
If a vehicle comes back for front brake pulsation after performing TSB 05-003-02 Rev B, it is likely that the TSB was not performed in its entirety. Do not perform the TSB again.
It is imperative that the following items are checked:
1. Thoroughly clean the surface of the wheel hub/bearing assembly where it mates to the brake rotor. The hub surface must be free of corrosion and dirt so that the brake rotor rests flush against the hub.
A. Make sure the back of the rotor (mating surface) is clean prior to installation.
B. Make sure the rust preventative is removed (cleaned) from the rotors prior to installation.
2. Each front brake rotor must be match mounted to the wheel hub/bearing to obtain the least amount of rotor lateral runout. The assembled lateral rotor runout of each rotor and hub assembly MUST BE verified to be 0.001 inch (0.025mm) or less. IF THIS Cannot BE ACHIEVED THROUGH MATCH MOUNTING THE ROTOR, THE ROTOR MUST BE MACHINED USING AN ON-THE-CAR LATHE.
3. The surface of the wheel where it mates with the rotor is cleaned of any corrosion and dirt.
4. The wheels are torqued to 100 ft/lbs.
We have a 99 GC Lmtd with a perpetual squeaky brake problem. New pads, rotors, cleaning, wiping, lubing, holding your mouth right, repeating the process several times in two years ---- nothing works for more than a month. Three different dealerships and no change. We have managed to get the squeaks into a different pitch just to break the boredom. Any clues?
Obviously, all of the above comments and problems about the warping of Jeep rotars are true. I bought an '02 Special Edition V8 new back in '02. At about 28k miles, my car started shaking when I braked so I took it into the Jeep Dealership. They knew exactly what I was talking about and replaced the brakes / rotars under warranty. They led me to believe that the problem was fixed for good, but now I'm over warranty (60k miles) and my car is shaking again. I can feel the warped rotars / brakes when I am applying light pressure to the brake pedal. It doesn't look like Jeep is going to do anything about it. Although I like my car, it will definitely be the last Jeep I ever buy.
Other problems: I have replaced my battery twice which may be normal. My car is often leaking water and I hope that this is normal with A/C usage. I just replaced a leaking radiator for $800 about three months ago. The switch which adjusts the heat / ac location (i.e. floor, body, defrost) broke and had that replaced by a friend for $100. I haven't experienced the window problems yet, but the comments are scary.
I'm not looking forward to replacing the rotars but I have to do it soon. I've been driving with a shaking car for about 6 months. If anyone has additional information where to buy the parts and which ones to buy, it is all very helpful. Thanks and looking forward to buying another Toyota, Honda or Nissan.
We own a 02 Cherokee Laredo 6 c 4.0. The only problem we have has thus far is it overheated and we are in the process of replacing the fan relay/sensor. We also bought new tires all around for $800. Had a minor heater core leak that was quickly fixed by son-in-law. Have to love the mechanic in the family!! Plan on taking it in to shop to see what recalls, if any, there are for our Jeep and get them taken care of. We have heard mention of a silent recall on the rotors. So to those of you who have this problem with the rotors, ask your dealership if there is a silent recall. Couldn't hurt to ask.
I own a 02 GC 4.7L for about a year now and have replaced the rotors twice! I even bought cross drilled rotors to help with cooling and ceramic pads, did nothing and guess what? I now have the never ending shaking happening again when I brake, this is ridiculous, I've been debating selling my Jeep. Mopar I expected better.
I too have a 2002 JGC; 67000 miles, 3 rotor jobs and all 4 windows have broken. There also were too many other small problems to mention.
I have a 2002 Jeep Grand Cherokee Sport, the rotors have been replaced or turned every 6 months since I bought it new. I am really getting tired of this problem.
I had the rotor warping problems on my 2002 Jeep with the upgraded caliper already on it. The whole problem with the rotors warping is people do not change the brake pads when getting rotors turned or replaced. The dealer turned and or replaced my rotors under warranty until about 40000 miles. They did this every 4 to 6 thousand miles due to warpage. The problem is they never replaced the pads. I took my front rotors off myself at 69000 miles, had the rotors turned and replaced the pads myself. Never had another warped rotor, it now has 98000 on it.
More of the same here. Bought my 02 Jeep GC in May of 2002 for the wife. She failed to mention the brake problem until the warranty was out. I noticed it at 40,000. Not too bad so I waited until 45,000 and replaced the rotors with cheap china rotors from Advanced Auto Parts. Replaced the pads with their mid-priced pads. Now has 115,000 miles with no further trouble with rotors or pads.
I bought my GC V8 new in Apr 02, and for the most part I really like it. Unfortunately I've had the same brake problems since around 25/30K miles, it's now at 64K. My husband thinks I'm crazy because I keep telling him the brakes are bad, he goes to have them changed and they look brand new. They've been replaced about 5Xs (most unnecessarily) since I've had the vehicle, and last year developed this great new ear-piercing squeaking that won't go away. The brakes AND rotors were replaced that time and again, all looked in excellent shape, but typical signs are still there of "needing new brakes" - e.g. pedal going down to the floor, brakes squeaking, some pulsating at higher speeds. Doesn't sound like there is a resolution, I like the car but I think the squeaking is going to drive me insane! I have to laugh at the earlier comment someone made of it being summer and driving with the windows down is unbearable, I feel the same way! It's going to be a long summer =(
I switched from the factory installed brake rotors on my 2002 Jeep Grand Cherokee to Akebono rotors and have had no problems. Apparently the factory installed rotors kept warping. Had them ground down every six months. Jeep is aware of the problem, but does nothing. It should have been a recall!!!
My daughter just bought a 02 GCL loaded with all the bells and whistles. "Dad...I hear a squeaking noise and when I brake, the steering wheel shakes back and forth" Here we go...I'll go the advance auto parts way first with cheap pads and rotors... I can do the change, it's not that hard. If it comes back again, we'll go with the caliper/slotted rotors/brake pad upgrade. KBB had the Jeep at $9k, she got it for $6500. She thought she was getting a deal...we'll see. I have a 05 Toy 4runner (bought new) with 110k miles...not one problem... not one! Have an 04 Chevy trailblazer with 97k miles... no problems the 2 years we've had it...What's up Mopar???
Update on my daughters 2002 GCL: Got new rotors and pads at advance auto for $150 and changed today. (cheapest they have) Made sure to clean surfaces very well where new rotor mates to wheel. Once the pads were out, I sprayed the calipers aggressively with brake cleaner before installing new pads. I also sprayed the protective oil coating off the new rotors with brake cleaner. If you have an 02, you have to know if they are Teves brake calipers (pre may 02) or Akebono calipers (post may 02)before pad purchase. Manufacture date of vehicle is inside drivers door panel. Ours were Teves. FYI-Her GCL is a V8.
I inspected the pads I removed and they were worn in a very uneven manner length wise. Probably about 1/8" difference from end to end of pad. That was on the inside pads, so it was only realized once the pads were removed. The outside pads wore uneven also but were not as bad.
Hope this helps someone, Pete.
Brakes work great for now!
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