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					Brake Pads

      REMOVAL & INSTALLATION




Removal & Installation


   1. Detach the brake caliper and secure to one side. Remove and discard the brake
      caliper retaining bolts.



   2. Remove the brake pads.

       NOTE

       If the piston is pushed back into the housing, brake fluid will be forced back into
       the fluid reservoir.



       NOTE

       The left-hand brake caliper piston retracts counter clockwise and the right-hand
       retracts clockwise.




To install:

   1. Using the special tools, fully retract the brake caliper piston.



   2. Install the brake pads.

       NOTE
      Make sure that the brake disc faces are clean before installation.



      NOTE

      Make sure the piston location mark is in the correct position so that the locator pin
      on the brake pad backing plate locates correctly into the piston.




   3. Install new brake caliper retaining bolts. Attach the brake caliper. Tighten to 27 ft.
      lbs. (32 Nm).



   4. Install the brake caliper damper. Tighten to 97 inch lbs. (11 Nm).




Through VIN M45254




Fig. Brake pads-S-Type

   1. Raise and support the vehicle.



   2. Remove the wheel.



   3. Disconnect the parking brake cable.



   4. Remove the caliper guide pin retaining bolts.
   5. Secure the caliper and anchor plate assembly out of the way to prevent damage to
      the brake hose.



   6. Remove the brake pads.




NOTE
If the pistons are pushed back into the housing, brake fluid will be forced back into the
fluid reservoir.


   1. Make sure that the brake disc faces are clean before installation.



   2. Make sure the piston location mark is in the correct position so that the locator pin
      on the pad back plate locates correctly into the piston.



   3. To install, reverse the removal procedure.



   4. Using the Snap On tool KS326, or equivalent, fully retract the brake caliper
      piston.



   5. Install new caliper guide pin retaining bolts. Torque to 24 ft. lbs. (33 Nm).




2001-03 XJ Range Through VIN F59525 Without Brembo Brakes 2001-04 Xk
Range Without Brembo Brakes

   1. Remove caliper housing from caliper carrier.
   2. Tie caliper housing aside.




NOTE
The inner brake pad is fitted with a clip which secures the pad into the caliper piston.


   1. Remove brake pads from caliper housing. Discard brake pads.



   2. Clean all mating surfaces.




NOTE
Retracting the caliper piston may cause the fluid reservoir to over-flow.


   1. Slowly retract piston into caliper housing.



   2. Clean caliper piston to pad mating surface.




To install:

   1. Remove paper backing from pads to reveal adhesive shim.



   2. Install brake pads, insert clip located on back of inner pad into caliper piston.



   3. Align housing to carrier.
   4. Install and tighten guide pins to 18-22 ft. lbs. (25-30 Nm).



   5. Install dust covers.



   6. Install anti-rattle spring.




From VIN G00442 Without Brembo Brakes

   1. Remove both rear wheels and tires. Detach the brake caliper.




NOTE
The brake caliper must be supported at all times.


   1. Remove the brake pads. Remove the brake pad anti-rattle spring plates.




NOTE
If the pistons are pushed back into the housing, brake fluid will be forced back into the
brake fluid reservoir.


   1. Make sure that the brake disc faces are clean before installation.
Fig. Rear brake pads-XJ Range 2003.5-04 from VIN G00442 without Brembo
brakes




Fig. Brake caliper piston tool-XJ Range 2003.5-04 from VIN G00442 without
Brembo brakes
       Fig. Make sure the brake caliper piston location mark is in the correct position so
       that the locator pin on the brake pad locates correctly into the brake caliper piston-
       XJ Range 2003.5-04 from VIN G00442 without Brembo brakes



WARNING
Brake pads must always be replaced in axle sets.


   1. Using the special tools, fully retract the brake caliper piston.




NOTE
Make sure the brake caliper piston location mark is in the correct position so that the
locator pin on the brake pad locates correctly into the brake caliper piston.


   1. Install new brake pads. Install the brake pad anti-rattle spring plates.



   2. Attach the caliper. Install new brake caliper lower retaining bolts. Tighten to 25 ft.
      lbs. (34 Nm).



   3. Install both rear wheels and tires.




WARNING
Do not start the engine or operate the electronic park brake before depressing the brake
pedal.


   1. Repeatedly depress the brake pedal until brake pressure is evident.
2001-03 XJ Range Through VIN F59525 With Brembo Brakes 2001-04 Xk Range
With Brembo Brakes

   1. Raise rear of vehicle and support on stands.



   2. Remove rear wheels.



   3. Loosen brake fluid reservoir-cap.



   4. Position a cloth around the reservoir to collect any fluid spillage.



   5. Remove pins from caliper. Remove anti-rattle spring. Discard brake pads.



   6. Clean all mating surfaces.
       Fig. Rear brake pads (3), anti-rattle spring (2) and retaining pins (1)-XJ Range
       2001-03 through VIN F59525 with Brembo brakes; 2001-04 XK Range with
       Brembo brakes



To install:




Fig. Apply a uniform layer of grease to back plate shoulders, making sure the whole
shoulder is covered-XJ Range 2001-03 through VIN F59525 with Brembo brakes; 2001-
04 XK Range with Brembo brakes


CAUTION
Make sure grease does not contact brake-pad friction surface or brake disc.


NOTE
To prevent brake squeal apply disc brake grease to the shoulders of the brake-pad back
plate. Apply a uniform layer of grease to back plate shoulders, making sure the whole
shoulder is covered.


NOTE
Retracting the caliper piston may cause the fluid reservoir to over-flow.


   1. Note condition of pins and replace if necessary.
  2. Slowly retract pistons into caliper. Install pads carefully, making sure that the
     grease on the shoulders is not disturbed. This is particularly relevant to the grease
     on the pad's trailing shoulder.



  3. Position anti-rattle spring.



  4. Install pins. Make sure pin collets are fully engaged into caliper.



  5. Install wheels.



  6. Remove stands and lower vehicle.



  7. Check brake fluid level is at the maximum mark.



  8. Remove cloth.



  9. Install cap.



  10. Start the engine and repeatedly press the brake pedal until brake pressure is
      evident.




From VIN G00442 With Brembo Brakes

  1. Remove both rear wheels and tires.
   2. Remove the brake pad retaining pins.



   3. Remove the brake pad anti-rattle spring plate.



   4. Remove the brake pads.




To install:


NOTE
If the pistons are pushed back into the housing, brake fluid will be forced back into the
brake fluid reservoir.


NOTE
Make sure the brake disc faces are clean before installation.


WARNING
Brake pads must always be replaced in axle sets.


WARNING
Make sure the brake pads are installed with the direction arrow facing downwards.


   1. To install, reverse the removal procedure. Using a suitable tool, fully retract the
      brake caliper pistons.




VIN M45255-N52047 Without Brembo Brakes

   1. Remove both rear wheels and tires.



   2. Detach the brake caliper.
   NOTE

   The brake caliper must be supported at all times.




3. Using a suitable tie strap, secure the caliper to one side.



4. Remove the brake pads.



5. Remove the brake pad anti-rattle spring plates.

   NOTE

   If the pistons are pushed back into the housing, brake fluid will be forced back
   into the brake fluid reservoir.




6. Make sure that the brake disc faces are clean before installation.

   NOTE

   Brake pads must always be replaced in axle sets.




7. Using the special tools, fully retract the brake caliper pistons.
    Fig. Make sure the brake caliper piston location mark is in the correct position so
    that the locator pin on the brake pad locates correctly into the brake caliper piston-
    S-Type 2002.5-06 VIN M45255-N52047 Without Brembo Brakes



8. Make sure the brake caliper piston location mark is in the correct position so that
   the locator pin on the brake pad locates correctly into the brake caliper piston.



9. Remove the forcing screw from the brake caliper piston retractor tool and install
   to the crankshaft pulley/damper remover.



10. Install new brake pads.



11. Install the brake pad anti-rattle spring plates.



12. Remove the tie strap.



13. Attach the caliper. Install new brake caliper retaining bolts. Tighten to 34Nm.
   14. Install both rear wheels and tires.



   15. Do not start the engine or operate the electronic park brake before depressing the
       brake pedal. Repeatedly depress the brake pedal until brake pressure is evident.




VIN G00442-G45703 With Brembo Brakes

   1. Remove both rear wheels and tires.



   2. Remove the brake pad retaining pins.



   3. Remove the brake pad anti-rattle spring plate.



   4. Remove the brake pads.




To install:


NOTE
If the pistons are pushed back into the housing, brake fluid will be forced back into the
brake fluid reservoir.


NOTE
Make sure the brake disc faces are clean before installation.


WARNING
Brake pads must always be replaced in axle sets.


WARNING
Make sure the brake pads are installed with the direction arrow facing downwards.


   1. To install, reverse the removal procedure. Using a suitable tool, fully retract the
      brake caliper pistons.




VIN G45704-G99999 With Or Without Brembo Brakes

   1. All vehicles:
          a. Remove both rear wheels and tires.



   2.
   3.
   4. Vehicles with high performance brakes: Remove the logo badge.



   5. All vehicles:
          a. Remove the anti-rattle spring.



           b. Remove the brake caliper retaining bolt dust covers.

              CAUTION

              The brake caliper must be supported at all times.




           c. Remove the brake caliper retaining bolts.



           d. Detach the brake caliper.



           e. Remove the brake pads.
   6.
   7.



To install:

   1. All vehicles:

        CAUTION

        As the piston is pushed back into the caliper housing, the brake fluid level in the
        reservoir will rise. Do not allow the reservoir to overflow.



        CAUTION

        If brake fluid comes into contact with the paintwork, the affected area must be
        immediately washed down with cold water.



        NOTE

        Only the extraction bolt from special tool 303-588 is used.



        NOTE

        Only the forcing plate from special tool 206-080 is used.



              a. Using the special tools, fully retract the brake caliper piston.

                 WARNING

                 Do not use compressed air to disperse brake dust into the atmosphere.



                 CAUTION
           Make sure the brake disc faces are clean before installation.



           CAUTION

           Brake pads must always be replaced in axle sets.



           NOTE

           Make sure that the brake pad with the anti-rattle spring is installed to the
           inboard side of the brake disc.




       b. To install, reverse the removal procedure. Tighten the caliper pins to 21 ft.
          lbs. (28 Nm).




2. Vehicles with high performance brakes: Install the logo badge: Tighten to 44 inch
   lbs. (5 Nm).



3. All vehicles:

   NOTE

   Do not start the engine or operate the electronic park brake before depressing the
   brake pedal.



       a. Repeatedly depress the brake pedal until brake pressure is evident.
VIN M45255-N52047 With Brembo Brakes

   1. Remove both rear wheels and tires.



   2. Remove the brake pad retaining pins. Remove the brake pad anti-rattle spring
      plate. Remove the brake pads.

      NOTE

      If the pistons are pushed back into the housing, brake fluid will be forced back
      into the brake fluid reservoir.



      NOTE

      Brake pads must always be replaced in axle sets. Make sure the brake pads are
      installed with the direction arrow facing downwards.




      Fig. Rear brake pads-S-Type 2002.5-06 VIN M45255-N52047 with Brembo
      brakes



   3. To install, reverse the removal procedure. Using a suitable tool, fully retract the
      brake caliper pistons.




Without Brembo Brakes
   1. Remove caliper housing from caliper carrier.



   2. Tie caliper housing aside.

       NOTE

       The inner brake pad is fitted with a clip which secures the pad into the caliper
       piston.




   3. Remove brake pads from caliper housing. Discard brake pads.



   4. Clean all mating surfaces.

       NOTE

       Retracting the caliper piston may cause the fluid reservoir to over-flow.




   5. Slowly retract piston into caliper housing.



   6. Clean caliper piston to pad mating surface.




To install:

   1. Remove paper backing from pads to reveal adhesive shim.



   2. Install brake pads, insert clip located on back of inner pad into caliper piston.
   3. Align housing to carrier.



   4. Install and tighten guide pins to 18-22 ft. lbs. (25-30 Nm).



   5. Install dust covers.



   6. Install anti-rattle spring.




VIN N52048-N99999 With or Without Brembo Brakes

   1. All vehicles
          a. Remove both rear wheels and tires.



   2.
   3.
   4. Vehicles with high performance brakes: Remove the logo badge.



   5. All vehicles:
          a. Remove the anti-rattle spring.



           b. Remove the brake caliper retaining bolt dust covers.

               CAUTION

               The brake caliper must be supported at all times.
           c. Remove the brake caliper retaining bolts.



           d. Detach the brake caliper.



           e. Remove the brake pads.



   6.
   7.



To installation:

   1. All vehicles:

        CAUTION

        As the piston is pushed back into the caliper housing, the brake fluid level in the
        reservoir will rise. Do not allow the reservoir to overflow.



        CAUTION

        If brake fluid comes into contact with the paintwork, the affected area must be
        immediately washed down with cold water.



        NOTE

        Only the extraction bolt from special tool 303-588 is used.



        NOTE

        Only the forcing plate from special tool 206-080 is used.
       a. Using the special tools, fully retract the brake caliper piston.

           WARNING

           Do not use compressed air to disperse brake dust into the atmosphere.



           CAUTION

           Make sure the brake disc faces are clean before installation.



           CAUTION

           Brake pads must always be replaced in axle sets.



           NOTE

           Make sure that the brake pad with the anti-rattle spring is installed to the
           inboard side of the brake disc.




       b. To install, reverse the removal procedure. Tighten the caliper pins to 21 ft.
          lbs. (28 Nm).




2. Vehicles with high performance brakes: Install the logo badge. Tighten to 44 inch
   lbs. (5 Nm).



3. All vehicles:

   NOTE
     Do not start the engine or operate the electronic park brake before depressing the
     brake pedal.



         a. Repeatedly depress the brake pedal until brake pressure is evident.




VIN G00442-G45703 Without Brembo Brakes

  1. Remove both rear wheels and tires. Detach the brake caliper.

     NOTE

     The brake caliper must be supported at all times.




  2. Remove the brake pads. Remove the brake pad anti-rattle spring plates.

     NOTE

     If the pistons are pushed back into the housing, brake fluid will be forced back
     into the brake fluid reservoir.




  3. Make sure that the brake disc faces are clean before installation.

     WARNING

     Brake pads must always be replaced in axle sets.
Fig. Rear brake pads-XJ Range 2003.5-06 VIN G00442-G45703 without Brembo
brakes




Fig. Brake caliper piston tool-XJ Range 2003.5-06 VIN G00442-G45703 without
Brembo brakes
   Fig. Make sure the brake caliper piston location mark is in the correct position so
   that the locator pin on the brake pad locates correctly into the brake caliper piston-
   XJ Range 2003.5-06 VIN G00442-G45703 without Brembo brakes



4. Using the special tools, fully retract the brake caliper piston.

   NOTE

   Make sure the brake caliper piston location mark is in the correct position so that
   the locator pin on the brake pad locates correctly into the brake caliper piston.




5. Install new brake pads. Install the brake pad anti-rattle spring plates.



6. Attach the caliper. Install new brake caliper lower retaining bolts. Tighten to 25 ft.
   lbs. (34 Nm).



7. Install both rear wheels and tires.

   WARNING
     Do not start the engine or operate the electronic park brake before depressing the
     brake pedal.




  8. Repeatedly depress the brake pedal until brake pressure is evident.




With Brembo Brakes

  1. Raise rear of vehicle and support on stands.



  2. Remove rear wheels.



  3. Loosen brake fluid reservoir-cap.



  4. Position a cloth around the reservoir to collect any fluid spillage.



  5. Remove pins from caliper. Remove anti-rattle spring. Discard brake pads.



  6. Clean all mating surfaces.
       Fig. Rear brake pads (3), anti-rattle spring (2) and retaining pins (1)-XJ Range
       2002-03 through VIN F59525 with Brembo brakes; 2002-06 XK Range with
       Brembo brakes




To install:




Fig. Apply a uniform layer of grease to back plate shoulders, making sure the whole
shoulder is covered-XJ Range 2002-03 through VIN F59525 with Brembo brakes; 2002-
06 XK Range with Brembo brakes


CAUTION
Make sure grease does not contact brake-pad friction surface or brake disc.


NOTE
To prevent brake squeal apply disc brake grease to the shoulders of the brake-pad back
plate. Apply a uniform layer of grease to back plate shoulders, making sure the whole
shoulder is covered.


NOTE
Retracting the caliper piston may cause the fluid reservoir to over-flow.
1. Note condition of pins and replace if necessary.



2. Slowly retract pistons into caliper. Install pads carefully, making sure that the
   grease on the shoulders is not disturbed. This is particularly relevant to the grease
   on the pad's trailing shoulder.



3. Position anti-rattle spring.



4. Install pins. Make sure pin collets are fully engaged into caliper.



5. Install wheels.



6. Remove stands and lower vehicle.



7. Check brake fluid level is at the maximum mark.



8. Remove cloth.



9. Install cap.



10. Start the engine and repeatedly press the brake pedal until brake pressure is
    evident.

				
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