[xj] rear caliper removal

XJ
21

In reply to a message from richinco sent Thu 14 Jul 2011:

Thank you for the reply. but I dont think it helps. The problem is
the parking brake lever attached to the caliper is what I cant
remove. It will not allow the caliper to rotate up enough. How do
you get the thing off? Im thinking a cutting tourch. (just kidding)
I’ve read all the posts I could find before asking this (including
the one pasted here) but no one seems to have mention the parking
break lever being an issue. Again, What am I missing? Richard–
richinco
monument colorado, United States
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22

In reply to a message from richinco sent Thu 14 Jul 2011:

Read the previous post carefully. Prise open the locking tabs and
remove the bolts/tabs and then rotate emergency brake pad holder
up on the rotor, just like it reads. It will pass under the edge of
the cage opening. Getting the tabs folded back will allow the bolts
to be unscrewed/removed–
The original message included these comments:

I’ve read all the posts I could find before asking this (including
the one pasted here) but no one seems to have mention the parking

–
Alyn
Seattle WA, United States
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23

Richard,
I believe you have repeatedly said that you can’t see what is holding the
handbrake in place.
On the top of each handbrake there is a brass retractor with fingers that
touch each handbrake pad. There are two almost vertically oriented bolts
that hold everything together. Metal lockplate tabs have to be bent down
to allow turning of the bolt heads.

Gene McGough
XJ6C II 1976
XK-150 FHC S834515DN----- Original Message -----
From: “richinco” r985beaver@yahoo.com
Sent: Thursday, July 14, 2011 6:27 PM

Thank you for the reply. but I dont think it helps. The problem is
the parking brake lever attached to the caliper is what I cant
remove.
Richard

richinco
monument colorado, United States

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24

In reply to a message from Gene McGough sent Thu 14 Jul 2011:

Richard:

I sent you the image of the rear brakes from the Jag CD. Without a
manual or the CD, working on these cars is very hard.

If this does not help, drop the IRS down and it will become very
clear how this all works.–
The original message included these comments:

On the top of each handbrake there is a brass retractor with fingers that
touch each handbrake pad. There are two almost vertically oriented bolts
that hold everything together. Metal lockplate tabs have to be bent down
to allow turning of the bolt heads.

–
'71 XJ6 383/200R, '72 XJ6 LT1/700R,'74 XJ6 383/700R
Glendora, CA, United States
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25

In reply to a message from richinco sent Thu 14 Jul 2011:

Gee they are a difficult thing do do without dropping the IRS.
Problem is that sometimes the handbrake pads can be put back
misaligned and not work properly.
I think from memory that when the handbrake caliper is
unbolted it comes backwards around the disc and out that
way,but the couple that I have done I have dropped the rear
end and by the way if you are replacing the rear foot brake
pads go to the extra measure of fitting an inexpensive kit
and (expensive) stainless pistons to the calipers.
As an added comment I believe that the handbrake pads bonded
to the plates are too easily unglued should somebody forget
to release the handbrake properly,they do overheat rather
quickly In my opinion they should be riveted and have a
squealer warning lug/clip on the edge
And if you are luicky enough to do the HB pads in place,dont
reconnect the cable until you work the individual levers
back and forth until by self adjustment they grab the disc–
The original message included these comments:

procedure. I’ve got it loose and rotate it up, but the hand brake
leaver hits on the top of the cage that surounds the rear end. I
need the caliper to go up another 2 inches to clear the bottom of
the cage. I dont see how the hand brake lever could be removed as I
cannot even fit a hand up ther let alone a wrench (even if I could

–
nifty 1
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26

In reply to a message from nifty 1 sent Fri 15 Jul 2011:

Thanks for all the replys. Including the emails. I droped the rear
end and found the hand break was froose to the caliper (rust) took
several blow to free it. Richard–
richinco
monument colorado, United States
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27

In reply to a message from richinco sent Sat 16 Jul 2011:

Also found this guy had a bunch of pictures posted if it helps
anyone in the future. http://one-more-time.us/jaguar/

richard–
richinco
monument colorado, United States
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28

In reply to a message from richinco sent Sat 16 Jul 2011:

Dear all,
I have a similar problem
‘‘the hand brake leaver hits on the top of the cage that s
surrounds the rear end.’’
But not the same as it is definitely not rusted on as there
is some play, but I do not see how to force the leaver down
to be able to slide the caliper round.
Are there any tricks I am missing?
I have a build up of rust on the edge of the disk that make
a kind of lip. Tomorrow I was thinking to knock it of with
a hammer? (gently) But thought I would see if there is
anything else I am missing.
I can just about turn the disk by rotating the wheel, but
the normal rear brakes are binding and hence the need to
remove them and rebuild the clipers.
Thanks Neil–
Jaguar XJ12 Series III Daimler saloon (1991), Spain
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29

In reply to a message from richinco sent Sat 16 Jul 2011:

Dear all,
I have a similar problem
‘‘the hand brake leaver hits on the top of the cage that s
surrounds the rear end.’’
But not the same as it is definitely not rusted on as there
is some play, but I do not see how to force the leaver down
to be able to slide the caliper round.
Are there any tricks I am missing?
I have a build up of rust on the edge of the disk that make
a kind of lip. Tomorrow I was thinking to knock it of with
a hammer? (gently) But thought I would see if there is
anything else I am missing.

Have you slackened the handbrake adjuster, Neil…

Both the handbrake and brake pads must be forced back to clear the disc
completely - giving more wriggle room, and to clear the ‘lip’ on the disc.
When forcing back the caliper pistons, be aware that they may stick due to
corrosion - causing the drag you mention. Excessive force bearing down on
the disk should be avoided due to the possibility of breaking the disk - and
some tricks may be required to free up the pistons. Also check that the
brake reservoir is around half full before forcing the pistons back - to
allow room for the fluid forced out as the pistons ae forced back

Also; the tie plate under the cage must be removed to give room for
extraction of calipers - and to give slightly more elbow room. The main
problem being of course the tight working space, particularly if some force
is required.

Frank
xj6 85 Sov Europe (UK/NZ)

I can just about turn the disk by rotating the wheel, but
the normal rear brakes are binding and hence the need to
remove them and rebuild the clipers.-----Original Message-----
From: Mex50
Sent: Tuesday, April 26, 2016 8:19 AM
To: xj@jag-lovers.org
Subject: Re: [xj] rear caliper removal

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30

In reply to a message from Frank sent Tue 26 Apr 2016:

Thanks for the reply Frank,

Yes handbrake caliper is loose, all bolts out and U shaped
holder is out. The tie plate was the first to come off. The caliper
caliper wobbles about a bit but does no want to move back a
and round.
I have started on the main brake caliper to see if it helps to
to have them both loose. With a bit more effort I am sure I ca
can get the brake pads out which should help a lot.

I�m slow, just an hour after work each day. I guess I just
have keep trying, be patient and practice my wobbling and
jiggling actions.–
Jaguar XJ12 Series III Daimler saloon (1991), Spain
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31

In reply to a message from Mex50 sent Tue 26 Apr 2016:

Hello Neil,

I imagine you are doing this work with the rear cage still
attached to that car. My experience is with it removed.

You are in Spain?

I live in Marbella/Estepona area if you require any help
etc?

Best

Malcoln–
Malcolm Young
Gauldry, NE Fife, United Kingdom
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32

In reply to a message from Mex50 sent Mon 25 Apr 2016:

Just to add my 2p worth, having recently completely
stripped my rear brakes in situ…

Remove handbrake cable from hand brake mech.

Remove top pins and u-shape brass plate holding caliper and
handbrake mech together…

Then I had to lever the handbrake mech out of the top of
the calliper where they are joined and where the top pins
had passed through ( carefully working from the side…for
which I had to remove the exhaust…joy…)

Once separated, I could then push handbrake mech upwards a
bit to create space…

Remove rear calliper brake pipe
Remove rear calliper pads
Remove rear calliper bolts…one flat at a time…

Pull calliper forward and out and then lower hand brake
mech and out…

One further tip I needed after being stuck, was that the
outer most handbrake pad can be dialled in/ out via a large
slot headed screw on the side of the handbrake mech - but
first you need to remove a split pin…this will make sense
when you see it and can be useful if you have a large lip
on the edge of the brake disc…

Cheers–
rich schofield
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33

In reply to a message from Frank sent Tue 26 Apr 2016:

Thanks for the reply Frank,

Yes handbrake caliper is loose, all bolts out and U shaped
holder is out. The tie plate was the first to come off. The caliper
caliper wobbles about a bit but does no want to move back a
and round.
I have started on the main brake caliper to see if it helps to
to have them both loose. With a bit more effort I am sure I ca
can get the brake pads out which should help a lot.

To remove the caliper its virtually essential to first remove the brake
pads, Neil - and to do that they must be forced back by leverage using the
disk as a lever point. The pistons are sometimes very recalcitrant - so both
patience and brute force is required…:slight_smile:

Frank
xj6 85 Sov Europe (UK/NZ)

I�m slow, just an hour after work each day. I guess I just
have keep trying, be patient and practice my wobbling and
jiggling actions.-----Original Message-----
From: Mex50
Sent: Wednesday, April 27, 2016 7:01 AM
To: xj@jag-lovers.org
Subject: Re: [xj] rear caliper removal

–
Jaguar XJ12 Series III Daimler saloon (1991), Spain
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34

In reply to a message from Frank sent Tue 26 Apr 2016:

Thanks for the reply Frank,

Yes handbrake caliper is loose, all bolts out and U shaped
holder is out. The tie plate was the first to come off. The caliper
caliper wobbles about a bit but does no want to move back a
and round.
I have started on the main brake caliper to see if it helps to
to have them both loose. With a bit more effort I am sure I ca
can get the brake pads out which should help a lot.

It’s virtually essential to remove the pads to remove the calipers Neil -
and to do that the pads must be forced back.
Which requires some leverage between pads and disc - and sometimes a lot of
patience…:slight_smile:

Frank
xj6 85 Sov Europe (UK/NZ)

I�m slow, just an hour after work each day. I guess I just
have keep trying, be patient and practice my wobbling and
jiggling actions.-----Original Message-----
From: Mex50
Sent: Wednesday, April 27, 2016 7:01 AM
To: xj@jag-lovers.org
Subject: Re: [xj] rear caliper removal

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35

In reply to a message from rich schofield sent Wed 27 Apr 2016:

Sounds very helpful Rich.
I will keep that all in mind.
I hope I can avoid removing the exhaust…
I am advancing, but need to buy a spanner extension to get
more leverage one of the main brake caliper bolts, boy they
are solid and my strength cannot budge the 2nd upper one.

Malcolm, well actually in the Republic of Catalonia. I
bought my car in Marbella, perhaps you saw her there a 1991
XJ12 saloon dark blue (Westminster blue!) and a beauty!

Neil–
Jaguar XJ12 Series III Daimler saloon (1991), Spain
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36

In reply to a message from Frank sent Tue 26 Apr 2016:

Thanks for the reply Frank,

Yes handbrake caliper is loose, all bolts out and U shaped
holder is out. The tie plate was the first to come off. The caliper
caliper wobbles about a bit but does no want to move back a
and round.
I have started on the main brake caliper to see if it helps to
to have them both loose. With a bit more effort I am sure I ca
can get the brake pads out which should help a lot.

To remove calipers it is virtually essential to first remove the pads,
Neil…

And to remove the pads you have to force the pads back from the disc, using
a lever against the disc, or agains the piston itself against the pad.
Sometimes a tricky do - the pistons may have corroded to the caliper body,
and excess force on the disc may break it. At the rear, the work space is
limited, up front adjustable plier can be used to rotate the pistons to
loosen them - at the rear it is…hm…more awkward. Ample use of brake
fluid on the pistons and your patient wobbling and jiggling will do it - but
the pads must come out…

And before forcing back the pistons; check that there is ample room in the
break reservoir - backflow may otherwise overflow it…messy…

Frank
xj6 85 Sov Europe (UK/NZ)

I�m slow, just an hour after work each day. I guess I just
have keep trying, be patient and practice my wobbling and
jiggling actions.-----Original Message-----
From: Mex50
Sent: Wednesday, April 27, 2016 7:01 AM
To: xj@jag-lovers.org
Subject: Re: [xj] rear caliper removal

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37

In reply to a message from Frank sent Thu 28 Apr 2016:

Dear Rich and Frank,

That did the job, thank you very much for your advise and en
encouragement.

When I got the main brake calipers loose (pads and mounting
bolts off) as you mentioned I could get the whole assembly
forward a bit and then I saw that even though I had removed
the bolts and holding U from the handbrake caliper it was
still firmly attached to the main caliper. I got a screw
driver in there and levered them apart and the then the
handbrake caliper slide back and round (as in the manual)
and I worked the main caliper out through the front. That pa
part completed!

The main caliper as suspected is a mess. Dust covers just frag
fragmented into pieces and the pistons are very rusty. A comp
complete rebuild with new pistons and seals.

I have to say I am already dreading putting that U shaped ho
holder back. I hope I can assemble it before sliding it up to
to the top as to get the U into place when I cannot see the ho
holes will be impossible!

Thank you Neil–
Jaguar XJ12 Series III Daimler saloon (1991), Spain
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38

In reply to a message from Frank sent Thu 28 Apr 2016:

Dear Rich and Frank,

That did the job, thank you very much for your advise and en
encouragement.

When I got the main brake calipers loose (pads and mounting
bolts off) as you mentioned I could get the whole assembly
forward a bit and then I saw that even though I had removed
the bolts and holding U from the handbrake caliper it was
still firmly attached to the main caliper. I got a screw
driver in there and levered them apart and the then the
handbrake caliper slide back and round (as in the manual)
and I worked the main caliper out through the front. That pa
part completed!

Good work, Neil - removing the rear calipers is not a walk in the park…:slight_smile:

I should also have mentioned that the brake fluid line should be capped at
removal - to prevent air and dirt ingress, it will ease the airing after
reassembly. Also, check the bores in the piston for signs of pitting
corrosion - if the bores are not smooth, downstream problems will occur. To
some extent the bores may be lapped - but extensive bore pitting may require
more extensive work, like professional resleeving - or caliper
replacement…

After reassembly, the pistons should be pushed fully in - again too reduce
airing the brakes, and attend to the retracting forks on the handbrake, they
are supposed to be replaced when worn hand brake pads are replace. And
refitting is fairly straight forward - the reversal of the removal, but
working by feel…:slight_smile:

Frank
xj6 85 Sov Europe (UK/NZ)

The main caliper as suspected is a mess. Dust covers just frag
fragmented into pieces and the pistons are very rusty. A comp
complete rebuild with new pistons and seals.

I have to say I am already dreading putting that U shaped ho
holder back. I hope I can assemble it before sliding it up to
to the top as to get the U into place when I cannot see the ho
holes will be impossible!-----Original Message-----
From: Mex50
Sent: Friday, April 29, 2016 5:19 PM
To: xj@jag-lovers.org
Subject: Re: [xj] rear caliper removal

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39

In reply to a message from Mex50 sent Wed 27 Apr 2016:

Hi Neil,

Yes I remember a dark blue V12 in our area. Beautiful car.

Catalonia is a tad far but if I’m up that way maybe we
could meet for a drink? Or vice versa?

Good luck,

Best

Malcolm–
The original message included these comments:

Malcolm, well actually in the Republic of Catalonia. I
bought my car in Marbella, perhaps you saw her there a 1991
XJ12 saloon dark blue (Westminster blue!) and a beauty!

–
Malcolm Young
Gauldry, NE Fife, United Kingdom
–Posted using Jag-lovers JagFORUM [forums.jag-lovers.org]–
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40

In reply to a message from Frank sent Fri 29 Apr 2016:

Good afternoon,
Thank you again Frank.
I have the caliper apart now and unfortunately I think I
need new calipers. The pistons are all pitted from the
rust. The inside of the caliper is much the same. All in front
front of the seal, but I think it would be false economy to
try and use the body of the caliper with new pistons. Not su
sure if that can be done?

Interestingly, after 5-6 hours to get the 1st caliper out I
did the second in 2 hours! Apart from taking bolts out a
1/100 of a turn at a time, my main problem was separating
the main caliper from the handbrake caliper as both sides were
were kind of corroded together.

Malcolm, sounds a nice idea, let me know if you are up this wa
way, especially if driving!

Neil–
Jaguar XJ12 Series III Daimler saloon (1991), Spain
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