1996-1998 (ZJ) Jeep® Grand Cherokee
1996-1999 (XJ) Jeep Cherokee
NOTE: This recall applies only to the above XJ model vehicles built through October 15, 1998 (MDH 1015XX).
NOTE: Only the above vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. (See "Owner Notification & Service Scheduling" section for a listing of salt belt states. )
IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject
Corrosion of the front brake rotors on about 635,000 of the above vehicles may cause separation of the rotor disc from the center hub (hat) section. This condition results from operating the vehicle for extended periods in geographic areas using large amounts of road salt for snow and ice removal. Rotor separation may cause a reduction of brake effectiveness for the affected wheel, which may increase stopping distance, cause the vehicle to pull to one side when braking and cause an accident without warning.
Repair
Both front brake rotors must be inspected and replaced if necessary. This recall does NOT include replacement of any other brake components. If other brake service is required (brake pads, caliper, etc. ), the additional associated costs are the owner’s responsibility.
Parts Information
IMPORTANT: Due to the likelihood that the required parts are already in dealer inventory, no parts will be distributed to involved dealers. Dealers may order as many rotors as necessary to support anticipated repairs.
Part Number Description
05015965AA Brake Rotor
Each part number above is for one brake rotor. Be sure to order two rotors per vehicle.
Service Procedure
Raise vehicle to working level on an appropriate hoist.
Remove both front wheel and tire assemblies.
Inspect both front brake rotors carefully for the presence of an "S" stamped on the face of the hat section (the "S" is very lightly stamped in the rotor face and may be difficult to read) (Figure 1).
If there is an "S" stamped on both rotors, the rotors have already been replaced with stainless steel rotors and do not require replacement. Reinstall the front wheel and tire assemblies and return the vehicle to the owner. No further action is necessary.
If neither rotor or only one rotor has an "S" stamped on it, continue with Step 4 to replace the rotor(s) without an "S" stamp.
Remove the caliper mounting bolts (Figure 2).
Tilt the top of the caliper outward (Figure 3). Use a pry tool if necessary.
Set the caliper aside (Figure 4). Secure the caliper to the suspension with a wire.
CAUTION: Do not allow the brake hose to support the weight of the caliper.
Remove the retainers that secure the brake rotor to the hub studs (Figure 5).
Remove and discard the brake rotor.
Clean the rotor hub and brake pad mounting ledges with a wire brush.
Remove the protective coating from the new rotor.
Install a new rotor on the hub.
NOTE: It is NOT necessary to inspect the new rotor for the presence of an "S" on the rotor face.
Install the caliper assembly (Figure 6). Position the mounting notches at the lower end of the brake shoes on the bottom mounting ledge and then rotate the caliper over the rotor and seat the notches at the upper end of the shoes on the mounting ledge.
Install the caliper mounting bolts and tighten to 132 in-lbs (15 N•m).
Repeat Steps 4-13 for the other front brake rotor (if necessary).
Install both front wheel and tire assemblies. Tighten the lug nuts to:
75 ft-lbs (102 N•m) on XJ vehicles.
88 ft-lbs (120 N•m) on ZJ vehicles.
Lower the vehicle.
Pump the brake pedal to seat the caliper piston(s).
Check the brake fluid level and adjust as necessary.
Road test the vehicle to verify proper brake operation.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Description Labor Op. No. Time
Inspect both front brake rotors 05879181 0. 2 hours
Replace both front brake rotors 05879182 0. 6 hours
Replace one front brake rotor 05879183 0. 4 hours
Add the cost of the brake rotor(s) plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.
Parts Return
Not required.
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging forservice of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD879".
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is attached.
Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Only vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. The following states are "Salt Belt" states:
Connecticut Michigan Pennsylvania
Illinois New Hampshire Rhode Island
Indiana New Jersey Vermont
Maine New York Washington, DC
Maryland Ohio Wisconsin
Massachusetts
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation
CIMS 482-00-85
800 Chrysler Drive East
Auburn Hills, Michigan 48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.
Customer Services Field Operations
DaimlerChrysler Corporation
SAFETY RECALL TO REPLACE YOUR VEHICLE’S FRONT BRAKE ROTORS
Dear Cherokee or Grand Cherokee Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
DaimlerChrysler Corporation has determined that a defect that relates to motor vehicle safety exists in some 1996-1999 Jeep® Cherokee and 1996-1998 Jeep Grand Cherokee vehicles.
The problem is... Corrosion of the front brake rotors on your vehicle (identified on the enclosed form) may cause separation of the rotor disc from the center hub section. This condition results from operating the vehicle for extended periods in geographic areas using large amounts of road salt for ice and snow removal. Rotor separation could result in a reduction of brake effectiveness for the affected wheel, which may increase stopping distance, cause the vehicle to pull to one side when braking and cause an accident without prior warning.
What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will inspect both front brake rotors and replace them if necessary. The work will take less than one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. This recall does NOT include replacement of any other brake components. If other brake service is required (brake pads, caliper, etc. ), the additional associated costs are the owner’s responsibility.
What you must do to ensure your safety... Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment.
Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer.
If you need help... If you have questions or concerns which the dealer is unable to resolve, please contact the DaimlerChrysler Customer Center at 1-800-992-1997. A representative will assist you. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S. W. , Washington, DC 20590, or call the toll-free Auto Safety Hotline at 1-800-424-9393. (Washington, DC area residents may call 1-202-366-0123. )
We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter.
Customer Services Field Operations
DaimlerChrysler Corporation
879
Attention: TDR Forum Junkies 
