Rear
REMOVE1. Remove handbrake calipers. Refer to SERVICE AND REPAIR / HANDBRAKE CALIPER.
Rear Brakes:
2. Remove three-way connector mounting bolt.
3. Remove plug brake lines at calipers (arrow) and position lines upward, away from from calipers. Fit plug to calipers.
4. Remove brake pads.
NOTE: Do not under any conditions, remove or attempt to remove bolts securing halves of caliper together.
5. Remove safety wire from caliper mounting bolts and remove bolts.
NOTE: Jaguar used two similar but different differentials and the brake disc's are different. The standard differential HAS a drain plug. The DANA differential has NO drain plug and the bottom of the unit is flat.
Caliper bolts for the standard differential, are located between caliper and differential housing. The lower bolts can be reached from underneath.
Caliper bolts for the Dana differential are accessed through holes in the brake disc, from the outside of the disc.
6. Slide caliper up and pull bottom of caliper forward, through opening.
Fig. 9 Rear Caliper Overhaul:
OVERHAUL
1. Remove bridge pipe and bleeder screw.
2. Place clean shop towel between caliper pistons and carefully feed compressed air into caliper brake line port to remove pistons, one at a time.
3. Carefully pry seal from recess in cylinder bore.
4. Remove dust seal from piston and cylinder bore.
5. Thoroughly clean caliper, cylinder bore, and piston using suitable brake cleaning fluid.
6. Carefully use compressed air to blow parts clean and dry.
7. Examine pistons for signs of abrasion, scuffing, scratches or corrosion. If any of above conditions are evident, a new piston must be used.
8. Coat new seal with brake lubricant, or new clean brake fluid.
9. Install new seal into recess in cylinder bore. Lubricate piston and install into cylinder bore.
10. Install new dust cover over piston and locate dust cover lip in outer groove of piston.
11. Push piston in fully and insert dust cover in outer groove of cylinder bore.
12. Repeat procedure for remaining piston.
13. Refit bridge pipe and bleeder screw.
REFIT
1. Fit mounting bolts to caliper and refit to differential. Tighten bolts to:
55 ft lbs (74.5 Nm)
2. Fit new safety wire to caliper mounting bolts.
3. Refit or renew brake pads.
4. Refit brake lines.
5. Refit connector mounting bolt.
6. Refit handbrake calipers.
7. Bleed brakes.