Thursday, February 26, 2015

How to change the brakes pads and rotors on your Jaguar XJS

Here is a detailed step by step description for changing the brake pads and rotors on your Jaguar XJS. This process also describes how to properly repack your bearings, working with grease is messy so I recommend plenty of rags available.

Products I personally recommend:
 Step by step description

  • First we have to remove the wheels. Set up the front of your car and remove your wheels. Then we have to start removing your brake pads. To do so you have to pull the two clips that hold the pins in place. They are behind the inner brake pad. Pull them with the needle nose pliers. Then with the same pair of pliers pull the pins (grabbing them from in between the pads) towards the inner side of the car. Watch for the clips so they don't jump and hit you in the eye :D.
  •  When you pull both clips and pins place all your brake hardware neatly aside.
  •  Here is your hardware:
  •  Now pull the pads with the needle nose pliers.
  •  Now you have to remove the calliper bolts. They are 19 mm and there are two. Remove them and set them neatly aside.
  •  Then you can pry off the calliper. But make sure you don't have a mess of tools, or parts below, when you remove the calliper a bunch of shims are going to fall. This affect the alignment and are important so save them! Set the calliper aside like in the photo below.
  •  Now is time to start removing the rotor. First you have to remove the dust cap with the tool I recommended at the beginning of the article:

  •  Here is a photo of the tool with the dust cap removed.
  •  Remove the cotter pin.
  •  Remove the nut holder (as you remove this parts set them aside BY ORDER)
  •  Remove the nut, I like to use small channel-locks (recommended at the beginning)
  •  Remove the bearing cover.
  •  Remove the smaller bearing.
  •  Here is a photo of all the pieces you should be setting aside in order of removal:

  •  Remove the rotor, it should pull out easily. Here is the rotor removed.
  •  Remove the bigger bearing and place with the rest of the parts. You need to clean all the grease (here is where all the rags come in handy)
  •  Wipe the spindle clean:
  •  Remove this 5 bolts that hold the brake rotor to the hub.
  •  These are the big bearing and the small bearing. We are going to clean them (with plenty of brake cleaner in the link above.)
  •  Hit it with brake clean until they look like this!
  •  Now place them on the bearing packer and press down.
  •  When you press down the bearing should be packed with grease:
  •  You need to remove all the grease from inside the hub (as much as you can don't go crazy) Then wipe the inside with a rag. Then put a bunch of new grease in there, all around the walls. Now go nuts but leave space remember the spindle goes through this hole, when you place is back the extra grease is gonna be displaced and wasted. Just put around the walls but leave space for the spindle to go through without displacing any grease.
  •  With a wire brush clean the surface where the rotor attaches the hub.
  •  Now place the rotor back in place, and catch the nuts by hand. Then tighten them. Very tight!
  •  Now to put it all back.
  •  Place the bigger bearing back first.
  •  Place the rotor assembly.
  •  Place the smaller bearing (in the right direction)
  •  Place the bearing cover.
  •  Now the nut. Snug it with the small Channel Locks. (this nut goes a bit tight by hand it doesn't go really tight or you'll mess up the bearings. Just SNUG it by hand and the small channel locks. Spin the rotor to make sure it spins freely but with no back and forth play. )
  •  Place the retainer for the nut.
  •  Place the new cotter pin and bent it in the following manner.
  •  Place the dust cap back and Hit THE EDGES with a punch and a small hammer. Don't hit the spheric part of the cap.

  • Now you need to place those rings that I told you before affect the alignment. They go between the calliper and the steering bar. Pry on the calliper with a screw driver and get them in place. Then with a smaller screw driver place it through the hole and align it.

  •  Now place the new calliper bolts in place. Tighten them. These go tight!
  •  Now is time to place the pads back in place. You might have to put the old pads back and push back on the pistons. Make sure you don't scrach the new rotor, pry against the rotor but with the tip of the screw driver stabbing the old brake pad.
  •  Place the new pads in place.
  •  Place the pins through, catching the clips. Then place the retainer clips through the holes behind the inner pad.
You did it. Now if you been reading my articles you know what I'm gonna say: Enjoy a cold beer and go through the other side!



    1. On good old Jags like the XJS rotors can be cut. But new modern Jags don't recommend cutting the rotors. Cutting rotors has been phased out in luxury cars and has been almost phased out entirely!

  2. I remember my recent problems with the driver license