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 rotorsprior to installation

2. Each front brake rotor must be match mounted to the wheel hub/bearingto 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 CAN NOT 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.

Date: August, 2002

To: Dealer Principal, Service Mgr, and Claims Admin Mgr.

Subject: 1999-2002 grand cherokee front brake pulsation, Ref: TSB 05-003-02 Rev A

Purpose: To clarify warranty coverage for brake rotors replaced under TSB 05-003-02 REV A.

Timing: Ongoing.

Policy: The owner's Warranty Information booklet states:

"...The Basic Limited Warranty covers the cost of all parts and labor needed to repair any defective item on your vehicle supplied by DaimlerChrysler Corporation that is defective in material, workmanship or factory preparation. …These warranty repairs or adjustments -- including all parts and labor connected with them -- will be made by your dealer at no charge..."

Action: If proper diagnostics determines that TSB 05-003-02 REV A is applicable to the vehicle, the left and right brake rotors must be replaced along with the front brake caliper package. This package contains, among other parts, the left and right front brake calipers, which according to the TSB are to be identified as the causal failed part. Brake calipers are covered for 3 years / 36,000 miles.

Since the brake caliper caused the brake rotors to fail, the brake rotors are automatically covered under the 3 year / 36,000 mile brake caliper warranty.

In accordance with the steps of the TSB, record the thickness variation specification for both rotors on the back of the hard copy of the repair order.

Any application of TSB 05-003-02 REV A beyond the 3 year / 36,000 mile New Vehicle Basic Limited Warranty requires authorization. Please ensure all dealership personnel are aware of this bulletin.

1. Original (from 1999 model production through May 10, 2002 (Teves, black color with open-sided bracket)

P/N 5011973AA Left front caliper MSRP: $141.00
P/N 5011972AA Right front caliper MSRP: $141.00
P/N 5018592AA Pad kit, front MSRP: $177.00
P/N 52098672 Rotor, front MSRP: $ 65.10 (each)

2. New (from May 11, 2002 production onward: (Akebono, silver color "fully closed" style)

P/N 5093181AA Left front caliper (all-new) MSRP: $140.00
P/N 5093180AA Right front caliper (all-new) MSRP: $140.00
P/N 5093183AA Pad kit, front (revised) MSRP: $ 177.00
P/N 52098672 Rotor, front (unchanged) MSRP: $ 65.10 (each)

3. New kit package (fits all 1999-2004 Grand Cherokees)

P/N 05093174AA Front caliper & pad kit package - (Includes left P/N 5093181AA and right P/N 5093180AA Akebono "fully closed" style calipers, revised P/N 5093183AA brake pads, P/N 5012437AA attachment bolts, and P/N 6035832 banjo sealing washers). MSRP $309.00

Alternate front disc brake parts sold by Mopar

P/N VWJA3183 Brake kit, front, model "Make It New" (MSRP $142.00)

P/N VOEA3183 Brake kit, front, model "Make It Original" (MSRP $225.00)

P/N V1013183 Pad kit, front. "Value-line" (MSRP $50.70)

P/N V3013183 Pad kit, front. "Value-line", Ceramic (MSRP $83.75)