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Service 3.4 L - Terry`s Jaguar Parts

1. Models affected Cars fitted with a Lockheed servo The vacuum cylinder oil Cosmolubic 100 recommended for lub rication of the vacuum cylinder see pages L 38 and L 42 of the 204 304 litre Service Manual has now been superseded by Shell Tellus 33 Shell Tellus 33 is available in eight ounce plastic bottles Jaguar Cars Limited 2005 JAGUAR Number L 8 Section Brakes Sheet 1 of 1 Date June 1961 INTRODUCTION OF CAST IRON BRAKE CYLINDERS Models affected Commencing Chassis Numbers R H Drive L H Drive 2 4 litre Mark 2 with disc wheels 106897 126283 2 4 litre Mark 2 with wire wheels 106839 126295 3 4 litre Mark 2 with disc wheels 154315 176964 3 4 litre Mark 2 with wire wheels 154321 176938 3 8 litre Mark 2 with disc wheels 203627 216474 3 8 litre Mark 2 with wire wheels 203576 216374 On cars with the above chassis numbers and onwards cast iron brake cylinder blocks replace malleable iron With this change tbe self adjustment arrangement is modified The spring washer shown in Fig 2 Section L of the Mark 2 Service Manual is no longer used the retraction being by a coil spring located in the piston Also whereas the original type had a separate piston and backing plate see Fig 14 Section L of the Mark 2 Service Manual the new type is of integral construction with no end plate It is therefore necessary when removing or replacing the piston seal or dust seal to stretch the rubber over the end of the piston W
2. Levelis found andthe foregoing checks do not i reveal reason For ilua ross pat fluid yl ever s tow enough to suggest g loss is definitely cccarring mexsure tro Pad level in tie reegt Leave car Stagair rinon cn ney Get Bg ran Lor 12 P nours and Te check level If levelehas dropped remove brak gt seryo iri toute giving re started engine disn trthemsexverand_cxoningeroveewidehce of brake fluid having entered the servo vacuyfy ey ka an the servo operating valve chamber If brake fluid is ARO ki EY Am ent servo or replace all the seals in the servo my LONG BRAKE PEDAL TRAVEL RECTIFIED BY BLEEDING SRAGES This complaint can only be due to air getting in the hydraulic system If you deal with a car on which the brake pedal has to be pumped when the car is stationary to obtain a normal brake pedal action but bleeding the system produces normal brake pedal action do not release the car until you have traced the reason for air getting into the hydraulic system 4 Possible causes are a Air entry past servo piston rod seal for Mark V11 and Mark VIL Clayton Dewandre servos ste Service Bulletin Nn 260 b Air entry past servo plunger seal 0 Air entry past wheel cylinder seals a Air entry past master oylinder main seal in this case bleeding will probably be difficult e Air in hydraulic system due to brakes having being overheated and the fluid vapouriscd LONG PEDAL TRAVEL SELF RECTIFIED Hui
3. No 10263 and is equally suitable for DUNLOP or GIRLING brake systems Jaguar Cars Limited 2005 JAGUAR Number L 50 Section Brakes Page 1 of 1 Date July 1968 VACUUM RESERVOIR CHECK VALVE In the interests of road safety all Jaguar Distributors are requested to inspect the condition of the vacuum reservoir check valve on models where the reservoir is fitted beneath the wheel arch Provision js made during manufacture to protect the valve agalnst salt corrosion butsadverse conditions may break through this protective coating It is therefore recommended that a check be made for correct operation at convenient servicing periods The valve and surrounding area should be thoroughly cleaned before removing for checking purposes and care should be taken to ensure that no dirt enters the system Any valve shown to be faulty must be replaced with a new unit no repairs being permissible Jaguar Cars Limited 2005 JAGUAR Number L 51 Section Brakes Page 1 OF 1 Date December 1968 BRAKE VACUUM RESERVOIR Mark 2 models It is apparent that the instructions regarding cxamination of the Brake Vacuum Reservoir fitted under the right hand front wing which were advised in Service Bulletin L 32 dated June 1964 have been ignored in some cases Attention is drawn to the requireme nt_for periodic inspection for security Additional anchorage was provided by the introduction of a Fixing Rdd Assembly secured between the
4. The September issue of the BRAKES section bulletin was incorrectly numbered Please alter this bulletin from L 21 to L 20 Jaguar Cars Limited 2005 JAGUAR Number L 23 Section Brakes Sheet 1 of 1 Date january 1963 INTRODUCTION OF MINTEX M 59 FRICTION PADS Model affected Commencing Chassis Numbers R H Drive L H Drive Mark 10 302914 352051 Commencing at the above chassis numbers Mintex M 59 brake friction pads Part number 9682 for set of 4 are fitted in place of Mintex M 33 pads The M 59 pads are identified bn stripes of brown and white paint on the end face the M 33 pads being identified by red and white stripes M 59 pads can be used to replace M 33 pads provided they are fitted in car sets 8 off It is also permissible to fit M 59 pads to E Types in car sets 8 but they should not be used on Mark 1 and Mark 2 cars Spares Bulletin No K 54 refers RETURNING MASTER CYLINDERS AND SERVO UNITS UNDER GUARANTEE All Models All distributors and dealers are requested to strictly observe the instructions given under Precautions to be observed when returning master cylinder and servo units in Service Bulletin L 8 If the units are not returned in the condition stated guarantee claims will not be accepted Jaguar Cars Limited 2005 JAGUAR Number L 25 Section Brakes Sheet 1 of 1 Date April 1963 INTRODUCTION OF HANDBRAKE CABLE SUPPORT BRACKET Models affected Commencing
5. adjacent to radiator header tank on cars with the 6 servo is no longer used and is replaced by a paper air cleaner mounted on the servo unit which requires renewing when the unit is overhauled In conjunction with this change the servo cowl vacuum tank and hydraulic pipes are also modified l a e Yo IB Goud i E AS O l l de il i i yen A A Pa wl yl ven Jaguar Cars Limited 2005 JAGUAR Number L 35 Section Brakes Sheet 1 of 1 Date October 1964 DISC BRAKE MASTER CYLINDER Mark 2 and 3 4 3 8 S models In the event of a complaint being received on one of the above models at a comparatively low mileage of lengthening brake pedal travel or sponginess which can be temporarily cured by bleeding the following instruction should be observed Fit a replacement master cylinder Part number C 16469 ensuring that the date of manufacture which is stamped on the identifica tion tag around the cylinder body is after 27 7 64 For easy identifica tion the tag is now in red polythene material AS Cars come in for service the feel of the brake pedal should be checked to avoid the possibility of this having been over looked by the owner NOTE NO ACTION IG NECESSARY UNLESS THE ABOVE MENTIONED CONDITION LS EVIDENT As there is no change in part number it is essential to observe the date of manufacture andwall master cylinders supplied in future from the Jagu
6. drive cara the patch late should be fitted to the third deoression from the rizht see sketch Using the patch date as a template mark ont the portion to ve cut out Cut out the portion marked so that when the plate is welded in position it will be flush with the surrounding metal Cores save Jaguar Cars Limited 2005 Bir BILLIE NC 241 3 If there is elrcedy a smell nateh late welded in the derression this can be cut out to allor the ateh nlate sun lied to be fitted Note On Risnt hand drive cars ic vill facilitate the use of a hacksaw if the szare whee cover late and scare whee are removed uodificotion to heel Auch The flange of the chassis s le mentor sho En ule gt c knocked back with a mallet flush with the box section as illustrated in the following sicctch Note 1t is TORTANG nise fouling wil ct o y a arry ous ine above tro body modifications other i ecn the handbrake compensator and take aluce Dei trunk floor and also betvveen une har brake cross cables and the wheel arches sition for Ri ht und Drive Cars Fosition for Left ES D r Hand Drive Cars Se a gr oS e sE R ty 3 ha ia X N pe ee y a K y D N as sy Ki Se i D 4 Es x d A i Si a X On d Ki 4 A bo got eer it eS A e We De E y TO s sg ZS zx gt a i 1 y KE e Je e Sa 1 j a ww Wi S ve sen E A KH DH ee D e i gt i D P
7. not having 2 cable cli besrin the nev oart number should be changed es soon as ig sresiicabic This overation is to bc carried out on a Zuaruntee basis irress ctive of the atc of the car The Distributor must withdsas from his Dealers all stocks of the following haster Cylinders Part Number Gr week 50 s 25 Ch Fah LUCO C 13100 anc 0 142 0 13675 and C 1 22 bers C 13100 reed for these iron oz Part numbers 1422h oy the Distributor incor orating stor Cylinder Repair Yit Part and 6 14295 ana the modified numbcr 7550 mee Part Tuber Dust xcluder VRO 1869 to Ring YBO 2417 Valve V39 3539 Seal van 3541 Serin Shere VRBO 3540 Ne Tuby of Ruducr Get VBO 3554 ldenti ication Cable clip VO 3532 and VBO 3553 Fittin Instruction Shict Sparc Perts replacement All stocks of the follovan parts hild by Dealers are to be returned to their ler en for ercait Part Number 5950 4 hes that roalace them vill no longer be supoiica nts The nev parts will form pert of new La Fart number 7660 She Distridutor is to serap out thes carts inoludins their own stoc s an sibuit a suerantes cloim for the parta sorzpoed PA AS 3 Cont Assas Jaguar Cars Limited 2005 FEBRUARY 1959 JAGUAR SERVICE AND SPARES ORGANISATION SERVICE BULLETIN NO 261 BRAKES MAINTENANCE AND RECTIFICATION IMPORTANT The following information is given to ensure more satisfactory bra
8. the adjusting bolt If the caliper is removed from the car it should now be refitted Pull and release the handbrake lever at the caliper con daa Gas Limited 2005 repeatedly when the ratchet will be heard to click over Repeat the operation until the ratchet will not operate which will indicate that the correct clegrance is maintained between the disc and friction linings Connect up the two cross cables to the handbrake operating levers and check the cable adjustment as follows Handbrake Cable Adjustment Fully release the handbrake lever in the car Slacken the locknut at the rear end of the main cable Adjust the length of the main cable by screwing the threaded end of the cable into the fork end to a point just short of where the handbrake operating Jevers at the calipers start to move Check the adjustment by pressing each handbrake operating lever at the same time towards the calipers if the top of the compensator on the rear axle tends to move appreciably the cable is too tight When correctly adjusted a certain amount of slackness in the cables will be apparent no attempt should be made to place the cables under tension otherwise the handbrakes may bind Jaguar Cars Limited 2005 JAGUAR Number L 12 Section Brakes Sheet 1 of 1 Date December 1961 MASTER CYLINDER PUSH ROD ADJUSTMENT Er Type A more efficient method of setting the brake master cylinder push rod clearance has been deviaed an
9. the rear axle Rerlace the existing bracket with Remove the self to the bracket attache securin the bracket e a a 4 uv the comnensator connected Adjust the handbrake Mes as follows Serey in the hendorake adjuster volt at each rear brake until the handbrake cads are in hard contact with the orale discs Fully release the handbrake lever Remove the clevis nin securing the fork end to the ocessting link at the front of the main cable Slacken Po SS ei ICH the locknut and adjust the cosition o the fork end so that with the clevis sin refitted there is no slack in the main cable and the two cross cables It is hovever imrortant to ensure that the ca les are not under Di a4 ension 3 7 th IER Unscrew th adjuster bolt and inset a 004 10 mm feeler zauge between the Psce on one handbrake pad the disc Screw in the adjuster bolt until the fecler gsuzge is just nipeed Withdraw feeler sauze and check disc for free rotation Repeat for the other side modification to busvase Compartment Floors To provide aceuuete clesrance Por the handbrake compensator in its nen position it is necessary to cut out one of the lon vitudonal denressions in the trank floor and eld in he patch plate rovided It vil be noted that there are six cepressions in the trunk floor for Left hand drive cars the patch slate should be fitved to the third depression fro the left and or rischt nan
10. the sorir surori i ivem 6 are Scho pniy the nek 1 components nth methylated 1 evaaircder tore for Snes o these defscts che mister oy y sucport te Se fo 7 Luoricete in to ES were 8 Slids the interna os the eg razo lwia snc fit of the evlinder Doc De no dp ars a anu LS sin CHS Ee E rubhcr yrease provided must be used for this the ens of the mester E A E ATAS cherour A TR UO rat Dody Wiig che lt n Gtcivgcmt pil ae mah cope tt ion bosses 9 CS p dust olla EE E ication kit NO in the motif l 1 i i E H z 5 yE pu er Ee q ARIAS AAA LL AA Lk i T s H i DH e seg ere e ENEE di j i eg SE S ageg Valve Bush Seal SP KS 5752 691 93 6950 gt eege f j tht 6 7 93 EAN KS i an i eae Y EEEE x H PA UNAS Deeg A 4 wan Bo e lt BS A a EPR SC ar E lve Seal SEVIS BULALTIF 0 246 o ZE ACPION EXPORT All Distributors viil bo susslied sith a small stock of mo ificd Master Cylindcrs Part aber 0 14580 ot 156 0 14579 2 4 lisre 3 4 litre together with e sunoly of Haster Cylinder Rensir Kits Part Number 7660 In cvery case hen n resort of long nedel action after siandinz is recvived the Master Cylinder is to bi changed imacdiately for the modifica t Vi c a D I It is also considerc Jesirebl that s11 Master Cylindcrs of the original tyse
11. 4 Adaptor plate C 13254 Cotidiano Jaguar Cars Limited 2005 SERVICI BULLETIN NO 236 CONT D De FOR CONVERTING RUM BHAKIS TO DISC BRAKES AUD DISC HEELS TO FIRE SFOKE HEELS Requirements Kit B fart number 7390 Kit Fart number 7391 plus items listed below to suit the particular model 2 4 litre 3 4 litre Handbrske compensator assembly R F Drive 13873 0 13875 L F Drive C 1387k C 13876 Vacuum Check Valve C 12790 Vacuum check mtg plate C 12798 Sleeve nut C 12799 off Bolt UB 125 72 off Setscrev UFS 12 5R off Plain washer e LO 2 off Spring washer 3G 104 X 4 off Nuts GR 125 2 a off Vacuum pipe 0 13963 1 off Vacuum pipe C 13952 1 off Hose check valve 6 13964 2 off Hose 0 14135 a off Hose 13965 1 of 0 13704 Adaptor plate C 13254 FOR CONVERT Requirements Kit C Fort number 73 PRICES Retail Price Kit A Part number 7389 100 including the individual items recuired Kit B pert number 7390 80 Cnel the indivizual itens requires Kit C Tart number 7391 93 Extras Fully chrome wire wheels extra cost per wheel 19 6d 2 4 Litre model cnly If converting from disc wheels to wire spoke wheels it will be necessary to fit the following aitditional parts e os D o Ls y Mi 2 5 inner tubes if existing tyres are tubeless type Sl 8 Od each 2 rear wheel valances cut out tyne Ele 2 Od each Index Reference Sect
12. Brakes a Rear brake self adjugvers inot operating 2 4 3 4 Litre only b Front brake self adjuster ratchet broken and or no friction on self adjustment friction pads e Front brake shoes incorrectly set up relativo to drums or drums badly out of round LONG PEDAL TRAVEL ON ROAD BUT NORMAL PEDAL TRAVEL EEN STATIONARY Disc Brakes a Excess play in front hub bearings b Excess end float of rear axle shafts c xcess run out on discs a Shake back on wheel cylinder pistons due to insufficient inter ference between piston seal and wheel cylinder bore see note under heading Long pedal travel self rectified when car has been standing Note If excess disc run out is found check the hub flanges for run out and for dirt between the hub flange and disc mating faces Also note when checking Mark 1X rear discs for run out or when setting the calipers relative to the discs the disc should be securely polted to the hub flange using suitable distance pieces under the wheel nuts Lockheed Drum Brakes a Insufficient friction or broken ratchet on front brake self adjusters Cont 1 de on Jaguar Cars Limited 2005 SERVICE BULLETIN NO 261 l pl Hydraulic check valve in end of servo Part No 6466 not main taining residual line pressure Girling Drum Brakes Insufficient friction on front brake sclf adjuster friction pads Heavy Pedal Action sometimes wrongly described by owners as fade l
13. CAR HAS Bian STANDING This complaint arises due to severe overhcating of the brakes and boiling of the brake fluid self rectified when fluid cools and can be due to JOE se rimited 2005 SERVICE PULTETTY 10 261 3 a Servo vacuum piston not fully returning and in this case all four brakes will show signs of having being overheated b Insufficient free mevement on master cylinder push rod again all four brakes with show signs of overheating c Automatic Transmission cars only Fault in anti creep pressure switch at rear of transmission unit holding rear brakes on Rear brakes only will show Signs of overheating a Car has been driven with hand brake on rear brakes only will show signs of overheating Note In the event of the brakes having been overheated the wheel cylinder piston seals should be examined In the case of disc brake cars overheating of the wheel cylinder piston seals will result in loss of interference and long pedal action ON ROAD LONG PEDAL TRAVEL ON ROAD AND HEN STATIONARY NOT CORRECTED BY BLEEDING This complaint is only likely to occur on drum brake cars for the following reasons Girling Brakes Mark Vill and Mark VII a Rear brakes not in adjustment SY TNS TLIStION Ste Pront prake Serr adjuster friction pads and brake shoes webs a Front brake shoes Incorrectly set up relative to drums see Sorvive Bullctin No 2567 of Grums badiy out _of round Lockheed
14. Chassis Numbers L H Drive 2 4 litre Mark 2 127083 3 4 litre Mark 2 179029 3 8 litre Mark 2 222332 In conjunction with the fitting of a 3 7 62 cm diameter propetter shaft to Mark 2 Overdrive Models See Service Bulletin G 5 it is necessary to attach a handbrake cable support bracket Part No C 22402 3 to L H Drive cars to ptrevent the cable fouling the larger diameter propeller shaft If the 3 7 62 cm diameter propeller shaft is fitted to cars already in service it will be necessary to fit the above bracket adjacent to the front seat belt floor anchor bracket AY in illustration Spares Bulletin No K 59 refers Jaguar Cars Limited 2005 JAGUAR Number L 28 Section Brakes Sheet 1 of 1 Date october 1963 BRAKE FLUID HANDBRAKE WARNING DEVICE All models Isolated cases have come to our notice where the warning light has remained on with the handbrake released and the brake fluid level correct This has been found to be due to a pressure difference between the inside and outside of tbe float container The remedy is to pierce do NOP dritt a 1 16 1 5mm hole through the float container in the position shown in the illustration mo St A E Jaguar Cars Limited 2005 JAGUAR Number L 50 Section Brakes Sheet 1 of 1 Date January 1964 HYDRAULIC FLUIDS FOR DISC BRAKE CARS It is important that the correct brake fluid is used in the Dunlop braking system
15. JAGUAR Number ad Section Brakes Sheet 1 of 2 Date January 1960 DISC BRAKE MASTER CYLINDER RECONDITIONING Models affected All cars fitted with disc brakes A new type of master oylinder is now fitted to cars with disc brakes and the assembly of internal parts supplied as a re conditioning kit Part number 8250 can be incorporated in the existing body of earlier type master cylinders when reconditioning master cylinders of that type Individual parts are not supplied separately The new type of master cylinder was introduced at the following chassis numbers RH Drive L H Drive 2 4 litre Mark 2 001 73 425120 3 4 litre Mark 2 150346 175144 3 8 litre Mark 2 200092 210676 Mark 1X 7713392 792257 XK 150 Open 2 seater 820066 832114 Drop Head Coupe 827506 838590 Fixed Head Coupe 825127 836635 When reconditioning a brake master cylinder of the type shown in Fig 1 attached the following procedure should be adopted 1 Remove the dust excluder from the head of the master cylinder 2 Remove the circlip using circlip type pliers if available alternatively round nose pliers may be used This will release the push rod complete with dished washer 3 Withdraw the piston and valve assembly complete with springs and supports 4 Discard the piston and valve assembly items 3 5 6 7 8 9 10 and 11 on Fig 1 and the circlip 12 Continued Jaguar Cars Limited 2005 5 Wash cylinder push rod rubber dust exc
16. RODUCTION OF BRAKE DISC SHIELDS Models affected Commencing chassis numbers R H Drive L H Drive 2 4 litre Mark 2 118052 127636 3 4 litre Mark 2 167631 179994 3 8 litre Mark 2 233264 223960 3 4 Tei 1B1838 1B25230 3 8 Tei 1B51607 1B75989 On cars with the above chassis numbers and onwards shields are fitted to the inside of the brake discs to reduce the tendency for the imer brake pad to wear more quiekly than the outer pad The shields can be fitted to cars prior to the above numbers if requested by Customers but at their own_cost If shields are fitted it will be necessary to cut off the corners of the bump Stop brackets and the lugs on the lower wishbone as shown in the illustration overleaf to avoid fouling of the shields on full lock Spares Bulletin No K 79 refers INTRODUCTION OF TYPE 8 8 20 3 cm LOCKHEED SERVO UNIT Models affected Commencing chassis numbers R H Drive L H Drive 5 4 s 1B2101 1B25286 3 8 IS 1B52037 1B76292 plus certain individual cars prior to these numbers Commencing with the above chassis numbers an 8 20 3 cm servo unit is fitted in place of the original 64 unit The new servo unit is of the diaphragm type in which there is no physical contact between the vacuum piston and cylinder The vacuum piston push rod is of a fixed length and there is no adjustment for clearance as there was on the 6 servo combi EE Jaguar Cars Limited 2005 The remote servo air cleaner fitted
17. Section Brakes Sheet 1 of 1 Date December 1961 BRAKE PEDAL BEARING Models affected Commencing Chassis Numbers R H Drive L H Drive E Type Fixed Head Coupe 860021 885105 Open 2 seater 850233 875859 On cars with the above chassis numbers and onwards the brass bush in the brake and clutch pedal housing is replaced by an impreg nated plastic bush Lubrication at the intervals recommended on Page L 9 Brake section of the E Type Service Manual and Pages 50 and 53 of the E Type Operating Handbook is now no longer necessary SELF ADJUSTING HANDBRAKE CONVERSION KIT Mark 2 models only Kits for converting the handbrake mechanism to the self adjusting type on Mark 2 models only are now available from the Spares Division The kit Part Number 8951 consists of the self adjusting handbrake assembly pivot bolts tab washer and retractor plate To fit the handbrake assembly the following procedure should be carried out Chock the front wheels jack up the back of the car and remove both rear road wheels Disconnect the short cables at the operating levers by removing the split pin and washer and withdrawing the clevis Pin Knock back the tabs and remove the pivot bolts together with the retractor plate and tab washer The handbrake assembly may now be withdrawn forwards Fit the self adjusting handbrake assembly into position fit the retractor plate ensuring that the retractor fingers are located in the holes in the pad c
18. Stoneguard on the Reservoir and the Vacuum Servo Cowl and the commencing Chassis numbers are quoted in Service Bulletin L 32 together with details of the items required and fixing instructions Ali Distributors and Dealers are urged to arrange for the Vacuum Reservoir and its mounting points to be carefully checked each time normal servicing is being carried out and THE FIXING ROD ASSEMBLY TO BE INSTALLED in all cases where this has not already been done No claim for parts when introducing this modification can now be allowed It is most important that inspection of the Reservoir mounting brackets etc should be carried out on all cars which have completed a fair mileage or have been subjected to long periods of standing Particularly careful examination is necessary following bad weather conditions when use of salt may have an adverse effect Jaguar Cars Limited 2005 JAGUAR Number L 68 Section Brakes Page 1 of 1 Date October 1970 LOCKHEED BRAKE VACUUM SERVO UNIT Models affected 2 4 3 4 litre Mark 1 2 4 3 4 3 8 litre Mark 2 240 340 Brake S rvo units fitted to the above_models are no longer supplied by Messrs Automotive Products Ltd on an exchange basis and the exchange scheme operated by Jaguar Cars Ltd therefore ceases forthwith It wili be necessary for Servo units to be overhauled by Distributors and Dealers for which purpose a compre hensive range of Service Kits are avajlable from Jaguar Spares Di
19. The part mmbers of the new type master cylinders are as follows Zelt litre 3 4 litre 3 8 litre Mark 2 Ce 16469 XK 150 C 161470 Mark 1X C 16471 The identification tab fitted to these types of master cylinders and the tab included in the reconditioning kit 8250 have a widened portion as indicated by the arrow in Fig 3 Cont de Jaguar Cars Limited 2005 Service Bulletin L 1 continued Sheet 2 of 2 MA aD FIG DISHED SPRING DUST SPRING EXCLUDER sii BODY SUPPORT VALVE SPRING cup a SEAL BL EE A E ae SS SE m i Ze ore 31100 1981 SEAL sun SPRING PUSH SUPPORT ROD cuncuip ENG VALVE RING FIG 2 Re A o e A FIG 3 E H Jaguar Cars Limited 2005 JAGUAR Number L 3 Section Brakes Sheet 1 of 1 Date March 1960 HANDBRAKE CONNECTING LINK Models affected Commencing Chassis numbers R H Drive L H Drive XK 150 Drop Head Coupe 827510 Fixed Head Coupe 836724 On cars with the above chassis numbers and onwards a longer handbrake connecting link is fitted to improve the efficiency of the handbrake The connecting link has two holes at its lower end and for maximm efficiency the pin securing Che Link to the handbrake cross shaft lever must be inserted in the lower hole The new connecting link Part number C 16866 may be Used to replace the previous link Part number C 8316 on cars prior to the above chassis mumbers VACUUM CYLINDER LUBRICANT
20. ala of brake fluid conforming to specification S A E 70 R3 such as Castrol Girling Crimson Brake Fluid Lockheed Super Heavy Duty Brake Fluid Dunlop Disc Brake Fluid Note Dunlop Disc Brake Fluid which is amber in colour will be supplied only in one quart or one half pint tins The reason for supplying fluid in comparatively small quantities is to avoid the possibility of water contamination resulting in lowering of the hoiling point or contamination due to the transfer of fluid from large containera to small measures Continued Jaguar Cars Limited 2005 which may have been used for other purposes Mixing of Fluids Note that Duniop Disc Brake Fluid can be mixed with other brake fluids of S A E 70 R3 specification If however there is any doubt regarding the specification of the brake fluid in the system it is advisable to bleed the system and refill with the correct fluid It is important to note that mixing S A E 70 R3 fluid with S A E 70 RI fluid will only result in S A E 70 RI performance Jaguar Cars Limited 2005 JAGUAR Number L 9 2nd issue Section Brakes Sheet 1 of 1 Date December 1962 This Service Bulletin supersedes the original issue of June 1961 which should be destroyed HYDRAULIC BRAKE FLUIDS With reference to the instructions issued in Service Bulletin number 275 headed Hydraulic Brake Fluids Important please note that with the introduction of a Dunlop Disc Brake Fluid the re
21. ar Spares Division will have been manufactured after 27 7 64 HOME DISTRIBUTORS AND DEALERS With regard to existing stocks will you please place an emergency order with our Spares Division for a sufficient quantity of master cylinders to cover your requirements and on receipt of these make the necessary arrangement for all stocks of C 16469 master cylinders manufactured prior to 27 7 64 to be returned for credit OVERSEAS DISTRIBUTORS With regard to existing stocks held by yourselves and your Dealers will you please place an emergency order with our Spares Division for a sufficient quantity of master cylinders to cover your requirements On receipt of these units will you make the necessary arrargements for all stocks of C 16469 master cylinders manufactured prior to 27 7 64 to be scrapped and confirm this in writing to the Service Division enclosing the identification tags from the cylinders when credit will be issued to you Jaguar Cars Limited 2005 JAGUAR Number L 36 Section Brakes Sheet 1 of 1 Date December 1964 BRAKE SQUEAL Series 2 Dunlop Disc Brakes Models affected Later Mark 1 2 4 and 3 4 litre Mark 2 2 4 3 4 and 3 8 litre Mark 1X XK 150 Mark 10 3 8 E Type 3 8 and 4 2 In Che event of this problem being encountered the following action should be taken Tt sbould be pnoted Chat occasional slight squeak on firstrapplication from cold must be_aceepted Brake noise can take the f
22. arriers fit the tab washer and secure the assembly with the pivot bolts knocking up the appropriate tabs Attach the cables to the operating levers opening the fork ends if necessary and secure with the original clevis pin and washer and new split pin Set the handbrakes and adjust the handbrake cable as described in Service Bulletin number L 10 This conversion kit cannot be fitted to Mark 1 mog bscars Limited 2005 JAGUAR Number L 17 Section Brakes Sheet 1 of 1 Date April 1962 SELF ADJUSTING HANDBRAKE CONVERSION KIT Mark 2 Models Despite the fact that a Service Bulletin Number L 13 has been issued on the subject we are receiving a great number of en quiries concerning the availability of a self adjusting handbrake conversion kit for earlier Mark 2 models As was advised the part number of the kit is 8951 and the retail price is included in the Master Parts Price List No allowance can be made for displaced material Fitting instructions are included in Service Bulletin number LT MODIFICATION TO OVERCOME KNOCK FROM SERVO ON BRAKE APPLICATION Models affected Commencing Chassis Numbers R H Drive L H Drive 2 4 litre Mark 2 112059 126724 3 4 litre Mark 2 159068 177962 3 8 litre Mark 2 207930 220553 On cars with the above chassis numbers and onwards a modified servo unit Part No C 19612 is fitted This unit incorporates a two stage air valve C Fig 21 on page L 22 of the Mark 2 Service Manual to reduc
23. commend ations are now as follows DUNLOP DISC BRAKE EQUIPPED CARS Preferred Fluid Dunkop Disc Brake Fluid S A E 70 R3 Alternative Fluids Recognised brandsof brake fluid conforming to specification S A E 70 R3 such as Castrol Girling Crimson Brake Fluid Lockheed Super Heavy Duty Fluid For Competition Use Races or Rallies Dunlop Disc Brake Racing Fluid Colcur Blue This fluid also conforms to S A E 70 R3 CARS EQUIPPED WITH DRUM BRAKES Earlier cars Recognised brands of brake fluid conforming to specification S A E 70 R3 such as Castrol Girling Crimson Brake Fluid Lockheed Super Heavy Duty Brake Fluid Dunlop Disc Brake Fluid SOO AA Jaguar Cars Limited 2005 Note Dunlop Disc Brake Fluid which is amber in colour will be supplied only in one quart or one half pint tins The reason for supplying fluid in comparatively small quantities is to avoid the possibility of water contamination resulting in lowering of the boiling point or contamination due to the transfer of fluid from large containers to small measures which may have been used for other purposes Mixing of Fluids Note that Dunlop Disc Brake Fluid can be mixed with other brake fluids of S A E 70 R3 specification If however there is any doubt regarding the specification of the brake fluid in the system it is advisable to bleed the system and refill with the correct fluid It is important to note that mixing S A E 70 R3 fluid wi
24. ctober 1964 BRAKE PULLING Mark 10 model If trouble is experienced with brakes pulling to one side which cannot be traced to an irregularity in the braking system the following check should be carried out Measure the relative heights of the outer ends of the steering drop arm and idle lever and if they are not within 1 16 1 6 mm of each other a suitable packing washer up to a maximum thickness of 3 32 2 4 mm should be fitted between the steering idler bracket and the front cross member until the above condition is obtained Tt will invariably be found that the washer needs to be fitted to the bottom bolt position of the idlersassembly and washer part number FW106T will usually be found to be suitable REPLACEMENT OF BRAKE SERVO UNDER GUARANTEE Mark 2 and 3 4 3 88 S models It has been established that Lockheed servo units are being replaced unnecessarily and consequently liability is being rejected against the terms of guarantee by the manufacturers If trouble is experienced with the braking system every possible effort must be made to establish the exact cause and to replace only the part concerned or carry out the necessary rectification In future if units are replaced unnecessarily the claim will be rejected and the unit concerned made available for collection by the distributor or dealer Jaguar Cars Limited 2005 JAGUAR Number 1 34 Section Brakes Sheet 1 of 1 Date October 1964 INT
25. d is as follows Ensure that the brake pedal and the servo operation lever are in the fully off position Adjust the top master cylinder push rod by slackening the lock nut and screwing the rod into the yoke 37 Fig 23 in the Brake section of the E Type Service Manual until all free play has been taken up Ensure that the booater operating lever 17 does not move from the fully off position Screw the push rod out of the yoke 37 1 3 of a turn that is two flats of the locknut and tighten up the locknut Check the adjustment by placing a screwdriver between the top of the balance link 29 and the pedal housing 4 and levering towards the master cylinders when the free play will be felt Note It is most important that the operating lever does not move from the fully off position this may be checked visually while adjusting the push rod REMOVAL AND REFITTING OF DISC BRAKE CALIPER CYLINDER BLOCK Cars with Quick Change Pad type Disc Brakes When the cylinder block has been removed from the brake caliper see Fig 14 Brake section of the Mark 2 Service Manual for any reason it is most important that one of the flats on the backing plate should be parallel to the support plate when refitting the cylinder block If the backing plate should be misaligned the support plate will be forced into contact with the brake disc by means of the piston backing plate Jaguar Cars Limited 2005 JAGUAR Number L 13
26. dbrake as fitted to current models The efficiency of the handbrake on Mark 1 cars is greatly improved with the fitting of this kit feont A orerecaceraieiars Jaguar Cars Limited 2005 Remove and discard the following parts Handbrake lever cross shaft to fork end Fork end from primary cable Handbrake compensator assembly R H Drive Handbrake pad carrier assemblies 4 off pan Fit the following parts i Self adjusting pad carrier R H for Square pad type brakes 9677 Self adjusting pad carrier L H for Square pad type brakes 2 Self adjusting pad carrier R H for Round pad type brakes 9676 Self adjusting pad carrier L H for Round pad type brakes Se Handbrake lever cross shaft to fork end R H D C 15511 opd Handbrake lever cross shaft to fork end L H D C 16213 4 Compensator assembly 2 4 litre ak ap 3 4 litre 720745 Si Cable compensator leyver to caliper Rn C 20635 Cable compensator lever to caliper L H C 20636 6 Primary cable G A Te Fork end C 14789 8 Universal jaw C 16214 9 Setscrew UFS 131 6R 10 Spring washer FG 105 X II Joint pin 6 off J 105 118 12 Split pin 7 off L 103 7U 13 Washer 7 off FW 105 T 14 Nut UFN 135 L 15 Joint pin J 105 12S The handbrake cable arrangement is shown on page L18 of the Mark 2 Service Manual For details of fitting instructions refer to pages L s 3 and 4 of the Mark 2 Service Manual Jaguar Cars Limi
27. ditionally if an extended continental journey is to be undertaken it is recommended that the fluid be renewed before departure if this has not already been done within the previous nine 9 months New Castrol Girling Crimson Brake and Clutch fluid to specification 70R3 should be used but in an emergency it is permissible to use a reputable brand of brake fluid provided it conforms to the correct specification For all flushing and cleansing purposes use Girling Cleaning Fluid which is specially produced and economically priced for this purpose Fluid from the system MUST be discarded Jaguar Cars Limited 2005 JAGUAR Number L 48 Section Brakes Page 1 of 1 Date July 1968 DUNLOP DISC BRAKE PRESERVATIVE FLUID Despite the information given in Bulletin L 31 March 1964 it is obvious from repeated complaints of sticky wheel cylinders etc received by Jaguar Service Division that advice given regarding the use of Dunlop Disc Brake Preservative Fluid is in the majority of cases being totally ignored It is considered ESSENTIAL in an attempt to mitigate the increasing number of complaints that the service detaits quoted in Bulletin L 3t be STRICTLY adhered to A11 Distributors and Dealers are requested to ensure that the need to use Disc Brake Preservative Fluid as an essential item when servicing the brakes is impressed upon Service staffs The fluid is available from Jaguar Spares Division in 8 oz tins Part
28. e Servo comecting hose vacuum pipe to inlet manifold take off collapsed 2 Vacuum check valve stuck or incorrectly assembled 3 Servo performance low sluggish piston or no interference between piston leather and vacuum cylinder be Long brake pedal travel resulting in maximum servo point being passed before full braking effort obtained see foregoing paragraph on Long Pedal Travel EXCESS BRAKING ON FRONT Iess Disc Brake Cars Rear brake pads sticking in calipers check by inserting fecler gauge between pad and disc and note if the feeler is nipped when the brakeg re ppiied Drum Brako Cars Sg a Set Imsa sei aod 9 Beas prak bes frotet incorrectly BRAKES HANGING ON a Brakes drag on all four whe ls fahi dp neh release when the engine is switched off Servo pist n sticking in vacum cylinder b Brakes drag on all four wheels b t release when engins is switched off Servo plungor valve sticking BRAKES PULLING LOCKING OR KNOCKING ON BRAKI APPLICATION The above complaints can be due to a wise Srake Dura Slackness of the bolts searing the brake caliper and or the bolts securing the caliper adaptor plate to the stub axle carrier or rear axle flange Drun Brake gars Slackness of the bolts searing the brake back late to the stub axle carrier or the rear axle flange b Grease or oil on the friction pads clean off grease or oil from the brake disc with petrol or trichloreythelene c On t
29. e noise on brake application The new cover and air valve assembly Part No 9205 is interchangeable with the previous type fitted The part number of Repair Kit which incorporates the two stage valve is 9211 Certain other changes to the servo unit took place at this point These are detailed in Spares Bulletin number K 43 Jaguar Cars Limited 2005 JAGUAR Number 1 21 Section Brakes Sheet 1 of 1 Date October 1962 SELF ADJUSTING HANDBRAKES IMPORTANT Disc brake models fitted with self adjusting handbrakes The following are revised instructions for refitting the handbrakes and renewing the handbrake friction pads in order to ensure centralisation of the pad carriers Failure to observe these instructions may cause a squeal from the handbrakes on cornering REFITTING THE HANDBRAKE ASSEMBLY Ensure that the handbrake pivot bolts are slack Remove the split pin fromethe head of the adjuster bolt and slacken the bolt until ther is approximately nm 6 35 mm free movement between the head and outer pad carrier Puli the inner and outer pad carriers away from the disc bending the brass retraction fingers until there is 1 16 1 6 mm clearance between each pad and the disc Take up the free movement at the adjuster bolt by tightening until the bolthead is in light contact with the outer pad carrier seating Fit a new split pin to lock the adjuster bolt Pull and release the handbrake lever repeatedly un
30. ers Tap back tie tab washers and remove the setscrew securing the inner pad carrier to the caliser Remove the inner nad carrier hen fitving the new carriers note that they are handed the tor cnd of the friction pad should SEH with the perthphery of the brake disc Ont deeeee Jaguar Cars Limited 2005 SERVICE BUSTI 70 241 Dive Fit the new inner pad carrier to the calirer usin a nev tab washer and setscret if necessary Lubricate the setscre with zine base grease on asse bly Attach the handoraie lever to the inner ped carrier as follows Place the lever agsinst the inner carrier Hold the locknut firmly against the outer face of the trunnion and screw in the edjuster bolt until three or four threads e ngage the Jlocknut Align the holes in the lever and pivot seats Fit the sivot sin and With the split pin er lock 11 Note The above rrocedure is described and illustrated under Relining the Handbreke in Disc Brake Descrintive and ieintenance Motes for the XK 150 model Do NOT fit the ivot pin connecting the lever to the inner cad carrier until the adjuster bolt has been screwed e few tirns into the locknut othersise the return scoring will not be reloaded Repeat for the other rear owe re Fitting the modified Compensator Bracket CH Disconnect the Pork end at th front end of the handbrake cable lockins nut which secures the handorake compensator d to the rear axle Remove the two setserews o
31. he Mark Vll Mark V111 and Mark 1X models slackness of the bolts securing the lower wishbone brackets to the chassis frame Slackness of the rear spring U bolts a On the 2 4 3 4 litre models slackness of the rear spring centre bolts WHISTLE FROM ANGINE An elusive whistle noticed at approximately 1200 r p m on a small throttle opening but not reproduced when car is stationary or coasting in neutral with engine switched off will be_traced to an air leak at the servo diaphragm chamber joint face lockh ed 6 Servo only Index Reference Scetion L Jaguar Cars Limited 2005
32. he brake fluid level in the reservoir is found to be low always make a careful check to find out WHY before topping up Jaguar Cars e ee a SERVICE BULLETIN NO 261 wa D o There will be a progressive reduction in level consistent with lining or pad wear due to the increased fluid volume contained in the wheel cylinders but if the fluid level has droped to any extent carefully check the following points for fluid loss l Push rod end of brake master cylinder If any trace of fluid is found on the push rod pull back the rubber boot and bscrve whether there is evidence of brake fluid leaking past the master cylinder piston seal If this condition exists fit a replacement master cylinder or overhaul the existing unit 22 Apply and maintain full pressure at the brake pedal and carefully examine all brake connections and wheel cylinders for fluid loss Note in the case of drum brake cars when checking the wheel cylinders pressure at the pedal should be maintained for some minutes and the drums then removed for inspection of the wheel cylinders If when pressure is maintained on the brake pedal the pedal progressively sinks examine all connections and wheel cylinders and if no fluid loss is found the loss of pressure should be traceable to the master cylinder recuperation seal or main seal Fit a replacement master cylinder or overhaul the existing unit Fully bleed the system and repeat the above pressure check tf Low fluid
33. hen replacing the piston seal it should be well lubricated with brake fluid and great care taken not to scratch or damage the inside surface of the seal or the groove in the piston PRECAUTIONS TO BE OBSERVED WHEN RETURNING MASTER CYLINDERS AND SERVO UNITS All Models When returning master cylinder and servo units to the factory distributors and dealers are requested to plug the hydraulic connections to prevent the possible ingress of mineral oil which may give a misleading impression of the condition of the rubber seals Usually it will be possible to use the plastic blanks provided in the replacement master cylinder or servo Und Limited 2005 JAGUAR Number L 9 Section Brakes Sheet 1 of 1 Date June 1961 HYDRAULIC BRAKE FLUIDS With reference to the instructions issued in Service Bulletin number 275 headed Hydraulic Brake Fluids Important please note that with the introduction of a Dunlop Disc Brake Fluid the recommend ations are now as follows DUNLOP DISC BRAKE EQUIPPED CARS Preferred Fluid Dunlop Disc Brake Fluid S A E 70 R3 Alternative Fluids Recognised brands of brake fluid conforming to specification S A E 70 R3 such as Castrol Girling Crimson Brake Fluid Lockheed Super Heavy Duty Fluid For Competition Use Races or Rallies coloured blue Dunlop Disc Brake Racing Fluid Spe 1282 58 This fluid also conforms to S A E 70 R3 CARS EQUIPPED WITH DRUM BRAKES Earlier cars Recognised s
34. her brake service carried out Jaguar Cars Limited 2005 JAGUAR Number L 39 Section Brakes Sheet 1 of 1 Date November 1965 IMPROVED HANDBRAKE ALIGNMENT Models affected Commencing Chassis No R H D LHD 2 4 Litre Mark 2 119356 127868 3 4 Litre Mark 2 169632 180262 3 8 Litre Mark 2 234 395 224207 From the above chassis numbers onward an improved method of handbrake caliper centralisation has been introduced to overcome any possible brake squeal Earlier cars may be moditied to this improved condition by fitting a Handbrake Alignment Kit Jaguar Part No 10792 as follows Fitting Place the prongs of the retraction plates in the holes in the pad carriers Position the lower Locating extension of the plates between the upper and lower bridge clamps and secure the clamps to the caliper with the original setscrews and locking tabs provided IMPORTANT The retraction plates contained in the kit are handed and when fitting these items it is ESSENTIAL to ensure that they are fitted correctly To check for the correct hand lay the two plates on a flat surface with the prongs and locating extensions projecting upwards It will be seen that one of the plates has a square cut face uppermost This retraction plate MUST ALWAYS be fitted to the left hand caliper Check that the retraction plate location extension is free to move between the bridge clamps when secured and that the handbrake mechanism is o
35. id reservoir Caps The covers give further protection to the brake fluid and to the level indicators The protective covers Part number C 23627 may be fitted to previous cars Jaguar Cars Limited 2005 JAGUAR Number L 31 Section Brakes Sheet 1 of 1 Date March 1964 DUNLOP DISC BRAKE PRESERVATIVE FLUID All disc brake models The preservative fluid mentioned in Service Bulletin L 29 is now available from the Jaguar Spares Division in 80z tins Part number 10263 The purpose of this fluid red in colour is to assist in preventing corrosion and should be used in the following manner when overhauling the calipers Before fitting the piston to the wheel cylinder coat the inside surface of the rubber dust cover with the preservative fluid paying particular attention to the edges Also lightly coat the dust cover where it fits in the annular groove in the piston Note There may be slight initial leakage of the preservative fluids past the dust cover and this may be confused with leakage of brake fluid past the piston seal If any doubt exists observation should be kept on the brake fluid lever Jaguar Cars Limited 2005 JAGUAR Number L 32 Section Brakes Sheet 1 of 1 Date june 1964 VACUUM RESERVOIR ATTACHMENT Mark 2 models Following some cases of severe salt corrosion affecting the attachment brackets for the vacuum reservoir under the right hand front wing resulting in fatigue it is es
36. ion L and M Jaguar Cars Limited 2005 SERVICI BULLETIN NO 236 CONT D De FOR CONVERTING RUM BHAKIS TO DISC BRAKES AUD DISC HEELS TO FIRE SFOKE HEELS Requirements Kit B fart number 7390 Kit Fart number 7391 plus items listed below to suit the particular model 2 4 litre 3 4 litre Handbrske compensator assembly R F Drive 13873 0 13875 L F Drive C 1387k C 13876 Vacuum Check Valve C 12790 Vacuum check mtg plate C 12798 Sleeve nut C 12799 off Bolt UB 125 72 off Setscrev UFS 12 5R off Plain washer e LO 2 off Spring washer 3G 104 X 4 off Nuts GR 125 2 a off Vacuum pipe 0 13963 1 off Vacuum pipe C 13952 1 off Hose check valve 6 13964 2 off Hose 0 14135 a off Hose 13965 1 of 0 13704 Adaptor plate C 13254 FOR CONVERT Requirements Kit C Fort number 73 PRICES Retail Price Kit A Part number 7389 100 including the individual items recuired Kit B pert number 7390 80 Cnel the indivizual itens requires Kit C Tart number 7391 93 Extras Fully chrome wire wheels extra cost per wheel 19 6d 2 4 Litre model cnly If converting from disc wheels to wire spoke wheels it will be necessary to fit the following aitditional parts e os D o Ls y Mi 2 5 inner tubes if existing tyres are tubeless type Sl 8 Od each 2 rear wheel valances cut out tyne Ele 2 Od each Index Reference Section L and M Jaguar Car
37. ion of the vacuum cylinder see pages L 38 and L 42 of the 204 304 litre Service Manual has now been superseded by Shell Tellus 33 Shell Tellus 33 is available in eight ounce plastic bottles Jaguar Cars Limited 2005 JAGUAR Number L 27 Section Brakes Sheet 1 or 1 Date August 1963 MODIFTED HANDBRAKE COMPENSATOR Model affected Commencing Chassis Numbers R H Drive L H Drive E Type Open 2 Seater 850728 879551 Fixed Head Coupe 861203 888760 Commencing at the above chassis numbers the handbrake compensator inner lever Link is replaced by an inner fork end C 22953 and outer fork end C 22954 which are attached to the compensator with a clevis pin J 105 10 The outer fork end has a serewed portion which retains the inner fork end wirt a locknut UFN 225 L and therefore provides a greater amount of movement to the self adjusting handbrake mechanism which is usually only necessary on initial assembly If trouble is experienced with the handbrake calipers binding due to insufficient range of adjustment in the handbrake mechanism the inner lever link canbe removed by drilling out the inner retaining pin and replacing with the aforementioned components Spares Bulletin No K 66 refers CONVERSION OF MARK 1 2 4 3 4 LITRE DISC BRAKED CARS TO SELF ADJUSTING HANDBRAKES A kit is now available from the Spares Division for converting Mark 1 2 4 3 4 litre disc brake cars to the self adjusting type han
38. isc run out due to machining of mounting flange or disc dirt between faces bent half shaft etc e Sticking master cylinder piston affecting front rear or all main pads depending on model Remedial Action a Remove pads check for any corrosion or dirt build up and that backing plate has been properly engaged with button on piston Check for undue marking on pad due to pressure by retaining clip Clean up all side faces of pads and refit b If retraction is still not satisfactory remove calipers thoroughly clean oft corrosion and acecumulated dirt but do not use abrasive which would destroy cadmium plating On Seri se2 brakes fit wheely cylinder assemblies incorporating recess around pad mounting button on piston _If satisfactory retraction is not obtained fit new caliper body using new wheel cylinder assemblies already on hand c Rectify end float condition in accordance with limits laid down in Service Manual 4 If excessive run out exists check hub flange face output flange face or for bent axle shaft as applicable and if satisfactory replace disc and re check e Check for sluggish return of master cylinder piston if evident service with appropriate repair kit providing cylinder bore is satisfactory SECTION B Symptom Running squeal or intermittent squeal when cornering Remedial Action 1 Check that handbrake operating system is free and permits full return of handbrake Note on Mar
39. k 2 cars the axle should be supporting the car to enable adjustment state to be checked 2 Check end float of rear discs 3 Check for oil contamination of handbrake 4 Check adjuster mechanism for free movement and freedom from corrosion 5 Re adjust handbrake mechanism in accordance with insta gmited 2005 in Service Bulletin No L 21 JAGUAR Number 1 38 Section Brakes Sheet 1 of 1 Date june 1965 MASTER CYLINDER MODIFIED TYPE Models affected Commencing chassis numbers R H Drive L H Drive 2 4 litre Mark 2 118651 127723 3 4 litre Mark 2 168663 180110 3 8 litre Mark 2 233790 224068 3 4 S Type 1B 2998 1B 25430 3 8 S Type 1B 53183 1B 77221 Commencing at the above chassis numbers a modified master cylinder Part number C 25425 is fitted The new master cylinder has a smaller diameter main spring than the previous type and the spring supports and piston are modified to suit Interchangeability The new master cylinder is interchangeable as an assembly with the previous type Part number C 16469 but certain of the internal parts are not interchangeable DISC BRAKE SHIELDS Mark 2 and 3 4 3 8 S The attention of Distributors and Dealers is drawn to Service Bulletin L 34 and the availability of shields to protect the discs of the above models Fitting of the shields materially help in reducing brake pad wear and customers should be advised to have these shields fitted when having ot
40. ke maintenance and to simplify the handling of complaints Contents Brake Maintenance ae dzs TE AT iia TE Ste Brake Fluid Level See Seis iao T seta SS sa Long Pedal Travel Self Rectified When Car Has Been Standing A 1 Long Pedal Travel Rectified by Bleeding Brakes ove 2 2 3 Long Pedal Travel on Road and When Stationary Not Corrected by Bleeding ese dwa siwe oes umes hong Pedal Travel or Road bub Normal Pedal Travel hen 3 Stationary Les Ae Ps e DER DER f Excess Braking on Fronts heels y an A Eso ee 4 Brake3 Hangingoon a AA 4 Brakes Pulling Locking On Khocking on Brake Application een 4 histle from Enging IA KAN see sa ae evans e 4 BRAKE MAINTENANCE i ER Ze Law D Ensure that only the brake fluids specified in Service Bulletin No 242 are used Check the brake fluid level in the Reservoir on every occasion a customers car is in your hands for service and if the level is low investigate as detailed below Check for brake lining or friction pad wear whenever you carry out regular maintenance service and advise the owner if re lining is necessary immediately or in the near future Fully bleed the hydraulic system and refill with new brake fluid whenever a brake re line or overhaul is carried out Check the condition of the rubber brake hoses and the rubber servo hose connections when carrying out a brake re line or overhaul RECTIFICATION BRAKE FLUID LEVEL If t
41. listed in the relevant Spare Parts Catalogues whist procedure for the overhaul of these units is fully described in applicable Service Manuals Jaguar Cars Limited 2005 January 1958 JiGUAR SERVICE AND SPARES ORGANIGATION SLRVICE BULLETIN NO 236 DISC BRAKES AND WIRE SLOCE SHERLS CONVERSION RECH Models affectec 2 4 litre dub Litre Dor customers vbo purchased zers just mior to the introduction of Disc brakes and ire spoke wheels zs ortions l equigment and who may have expressed 2 desire to nave their cars converted the above kits are now available from the Jaguar Spares Department Instructions for carrying out these conversions wild be included with euch Kit Reauests for these kits should be made sn separate order form and the following particulars given Model 2 litre or 3 4 litre Right hind or L ft cod 9 Chassis number of vehicle if possible Y FOR COMVERTIAS DRUM BE ARES TO DISC BRAKES ONLY ar model 2 4 litre eh litre Handbrake compensator assembly R H Drive 0 13373 6 13875 D H Drive 13874 0 13876 Pm Check Valve C 12790 Vacuum check mtg plate 0 22798 Sleeve nut gt 0 12799 2 off Bolt UFS 125 78 2 off Setscrew JFS SE off Plain washer p 7 105 7 2 off Spring washer FG 10L X 4 off Nuts NN 125 L 2 off Vacuum pipe 0 13953 1 off Vacuua pipe 4 13962 1 off Hose check valve 6 13964 7 off Hose 0 14135 1 off Hose e C 13965 1 off C 1370
42. luder in methylated spirit or clean brake fluid Check that cylinder bore is in good condition and that dust excluder and dished washer are undamaged 6 As the piston and valve assembly are not anchored together ensure during fitting that the piston end of the valve stem locates in the piston bore See Fig 2 7 Lubricate the cylinder bore with brake fluid insert the piston and valve assembly until the piston fitting sleeve engages in the mouth of the cylinder Push the piston firmly through the fitting Sleeve and remove the sleeve when the piston assembly is fully home in the cylinder bore Note A special lubricant is packed between piston seals therefore it is important that fitting sleeve is not removed until piston is correctly located in cylinder 8 Position the push rod and depress the piston sufficiently to allow the dished washer to seat on the shoulder at the head of the cylinder Fit the new circlip and cheok that it fully engages the groove 9 Fill the dust excluder with clean Wakefield Rubber Grease H 95 59 Tube in kit 10 Reseat the dust excluder around the head of the master cylinder 11 Remove the existing identification tab and fit new tab supplied Note During the whole of the servicing operation use only clean brake fluid Wakefield Crimson to SAE 70R1 After refitting the master cylinder to the car and bleeding the system make a careful check of all units pipes and fittings for leaks
43. ollowing forms a Heavy squeal on most applications b Running squeak due to contact between main pads and disc c Running squeak due to contact between handbrake pads and rear discs a Intermittent squeak pronounced when cornering due to hand brake pads in contact with rear discs Rectification falls into two categories Attention to main pads See Section A Attention to handbrake mechanism See Section B The causes and remedial measures are not shown as a sequence of operation but Distributors and Dealers will act according to their findings SECTION A Symptom Heavy squeal on application or continuous running squeak without application 1 Check that pads are all free in guides Push back piston fully and refit pads correctly on pistons 2 Check whether disc turns freely or that clearance exists between all main pads and discs when pedal is released after application Lack of clearance indicates inadequate retraction for some reason Jaguar Cars Limited 2005 Ps AAA NOTE Use light pressure only approximately 10 lbs 4 5 kg pedal effort If unbedded pads are fitted clearance may not be measurable but disc should turn reasonably freely by hand Lack of retraction may be due to a Pads sticking in caliper b Wheel cylinder pistons sticking in cylinder or guide location for backing plate c Disc float due to excess end float in front hub bearings or axle shaft as case may be d D
44. pe ei 8 d ER 1 Z a al k N gt Got D p kW 3 1 Li DN l 3 Ge La V N b t fing ge E d S e aye lt p Ce a j Kei N yx NW moO a e z n SE Y EC Ze a S i N KR e E H i d ES N D e inf EI i e D Ki Sa S Oe EA D e j ZE m s S NM SCH KM gt y R GE S we xw d f T 2 a gt gt e e N S A E Se E e q i a RN Pi a E y Jaguar Cars Limited 2005 LODUPECATECH To PE SiS e ee ee Ae KC ENER o New Condition D T eg sesion age E i gt A 5 A y y A 3 4 S Z HM S d M 4 1 Y E ee vine ze H a D E re E en inde Reference Sections L and N Jaguar Cars Limited 2005 Jk FCE AED 3 SUR ek 3 OR GENTS SRVIC BULL TA NO 246 Le ne oa TOF TO Es Sa eed hogcla of reed 2 4 lite cars Pitted with 5 4 kitre cars fitsea th X 150 cars fittca with rise breke To deal sith cases there a ex erienced on the first been standing but normal the sedal the follo in commencing with chassis numbci s 2 4 Jitre Sede Lin Xx 150 Coen seater 159 Drop Ze id Coupe nk 150 Fi xea heed cou Jee lon acolicaticn of the vrs regal action is out modification has been in rocuced in croduction TEE 2 SREK MAIER CYLINDER aiso bralics isc Deloos ER 3 Ce Se a brake ode ake pedal hen ainca on the Riz ut hans drive 2 ection is AY 1958 T ON sometine
45. perating satisfactorily Jaguar Cars Limited 2005 JAGUAR Number 1 44 Section Brakes Page 1 of 1 Date September 1966 BRAKE FLUID CASTROL GIRLING DUNLOP Disc Brake Clutch Fluid Recommended Hydraulic Fluid in current Owner s Handbooks and Service Manuals has now been deleted from the specification and replaced with CASTROL GIRLING CRIMSON CYutch Brake Fluid This fluid atso eonforms to A E 70R3 specification with a high boiling point factor but it is desirable that it should not be mixed with other fluids The new fluid can be readilty identified by the colour which is deep crimson Jaguar Cars Limited 2005 JAGUAR Number 1 47 Section Brakes Page 1 of 1 Date January 1968 BRAKE FLUID RECOMVENDATIONS ALL MODELS To all Distributors and Dealers Your attention is drawn to Lhe point that although modern brake fluids to 70R3 specification are not affected by metal alloys mouldings and rubber parts used in the braking system they can however absorb moisture from the atmosphere to varying degrees Any moisture content will lower the resistance to freezing and seriously reduce the temperature at which the fluid will boil This deterioration if sight may not render the brakes unsafe for ordinary use but full braking power im an emergeney or for use in mountainous country may be affected It is therefore strongly recommended that the brake fluid be renewed every eighteen 18 months Ad
46. s the car has second action of Lett Heng drive 313035 988746 830438 837134 335566 Exter wT but is identified by a ceble clip beat retest nmocrs Fitted to the barrel of the Mast r flen c fittinz and the out let bosz 150 VBL 3248 frry RAA Late cis CU 5249 Ca The follo in parts become rcdundant Part Tuinocr 6950 Seal Item 9 Plate on sage 21 of the Dis Brake Svare Farts Catalogue 5949 Bush item 10 it gt i 0952 Valve Leon Fy A u P E9LL spring Suscort Item 6 n n and are rerlace by the following nex parts Runloo Part Kouer BO 3541 Scal VBO 3539 130 3540 Susrort Note A sesarate bush for th scal is no lonver uscd The Sravings on the nert sage show the difference between the old an the new parts The differences betvcen the old and ne carts arc casily recognisable exccot in the casg of the sin eupsorta botoe n nich there is no visible ciffcxonce The olf oe swin tacsort mut not in any instance Dt refitied OOIE eama Jaguar Cars Limited 2005 FO 246 res Csetalorue uoh buen n of tae mas eircli 1 With ray th cylinder pe 2 Remove the Key 4 Discard the valve seal 9 suprort 6 and IC 5 Glean the cylinder garit oz by entre dare ang scoring cylinder must be res oy fh SSE GEE 6 Urine the nes comnonent ey SG and Dj sho tac sketch below cos emble d shoin und ret them ne valve G g a che cnir bors of
47. s Limited 2005 March 1958 BERRY LCF AMD PARS ORGANISATION SVIS BUE TEN NO 241 MODIFICATION SO OM HA BRAM CROSS CABLES FOULING BODY oe ee e ew a iwodels affected 2 4 litre cars fitted with disc brakes 3 4 litre cars fitt d with disc brakes If complaints are received of the handbrake cross cables fouling the rear whecl arch when the car is heavily laden the following modification can be carried out on a guarantee oasis This modification was introducdin procuction at the following chassis numbers R E Drive L H Drives 2 4 litre 510118 942654 Dok Mire 972401 988246 Farts required TU hand 749 6926 Ea 105 11 Pe E FW 105 T Pl neiasher dl 2 L 102 4U Sakit ia 2 L 103 7U Solit pin ff 2 6925 Setscrew segir Hendbreke to Caliper 2 6932 Teb washer a oS LA 2 C 13871 Handbrake cross cable E C 13872 Handorake cross cable 1 Fandorake Comsensator Bracket as detuiled below for various models 14258 2 4 litre Right hand drive Ze C 14259 2 4 litre Left kend drive i 2 14260 3 4 litre Right hand drive 1 CIA GRASS 3 4 litre Left hand drive E 71481 Lugyase compartment floor natch plate 1 Modification to Caliper Handbrake 9 AA v Tt is necessary to rerlace each inner pad carrier and lever with the modified type supnlied Disconnect the handbrake cross cable froin the handoiake lever Unscrew tre acjuster bolt comrletely to sesarate the inner and outer pad carri
48. s fitted to Jaguar cars and we wish to draw your attention to our recommendation for Dunlop Disc Brake Fluid which is also being used for initial filling in the factory Dunlop Disc Brake Fluid has a high boiling point and it has been developed especially to suit the requirements of the Dunlop braking system Supplies are available world wide from Castrol Limited who produce and market this fluid exclusively for Dunlop In the event of the fluid not being locally available only fluid guaranteed to conform to S A E 70 R3 specification which is fully miscible with Dunlop Disc Brake Fluid may be uscd as an alternative The use of fluids other than that recommended may cause rapid deterioration of the rubbei seals Eubricating oil petrol and paraffin are harmful to the rubber seals and great care must be taken to avoid contamination from vessels or funnels when filling brake systems The boiling point ofvall brake fluids is reduced by water contamination and caps on containers must therefore be replaced after use to prevent the fluid absorbing moisture from the atmosphere It is also recommended that the fluid in the system is changed approximately every 25 000 miles 40 000 km BRAKE FLUID RESERVOIR CAP COVER Models affected Commencing chassis numbers R H Drive L H Drive E Type Open 2 seater 850807 880760 Fixed head coupe 861427 889697 Commencing at the above chassis numbers protective covers are provided over the brake flu
49. sential that the Fixing Rod Assembly used on later Mark 2 cars should be fitted At the same time the fixing brackets should be examined Distributors and Dealers should arrange this as cars come in for service and details of parts required together with chassis numbers after which the fixing rod was fitted in production are given below A claim may be submitted for the parts shown only R H Drive L H Drive 2 4 Pitre Mark 2 116200 127334 3 4 litre Mark 2 164495 179522 3 8 litre Mark 251603 223125 Part No Description No off C 22425 Fixing rod assembiy for stoneguard 1 UFN 119 L Nut 2 Ge r Shakeproof washer 2 UFS 119 4R Setscrew 1 The fixing rod is fitted between the reservoir and the vacuum servo cowl It will be necessary to drill 13 64 5 2 mm holes in the cowl and reservoir flange to take the fixing rod and setscrew Spares Bulletin K 67 refers BRAKE BLEED NIPPLES RE POSITIONED Models affected Commencing chassis numbers RH Drive L H Drive 2 4 litre Mark 2 117537 127516 3 4 litre Mark 2 166443 179812 3 8 litre Mark 2 232583 223561 Commencing at the above chassis numbers the position of the brake bleed nipple is changed from the outside to the inside of each caliper The hydraulic pipes are modified to suit This allows the brakes to be bled with the wheels in position if so desired Jaguar Cars Limited 2005 Speres Bulletin K 73 refers JAGUAR Number L 33 Section Brakes Sheet 1 of 1 Date O
50. ted 2005 JAGUAR Number L 36 Section Brakes Sheet 1 of 1 Date December 1964 BRAKE SQUEAL Series 2 Dunlop Disc Brakes Models affected Later Mark 1 2 4 and 3 4 litre Mark 2 2 4 3 4 and 3 8 litre Mark 1X XK 150 Mark 10 3 8 E Type 3 8 and 4 2 In Che event of this problem being encountered the following action should be taken Tt sbould be pnoted Chat occasional slight squeak on firstrapplication from cold must be_aceepted Brake noise can take the following forms a Heavy squeal on most applications b Running squeak due to contact between main pads and disc c Running squeak due to contact between handbrake pads and rear discs a Intermittent squeak pronounced when cornering due to hand brake pads in contact with rear discs Rectification falls into two categories Attention to main pads See Section A Attention to handbrake mechanism See Section B The causes and remedial measures are not shown as a sequence of operation but Distributors and Dealers will act according to their findings SECTION A Symptom Heavy squeal on application or continuous running squeak without application 1 Check that pads are all free in guides Push back piston fully and refit pads correctly on pistons 2 Check whether disc turns freely or that clearance exists between all main pads and discs when pedal is released after application Lack of clearance indicates inadequate retrac
51. th S A E ZO Ri fluid will only result in S A E 70 Rl performance Jaguar Cars Limited 2005 JAGUAR Number L 10 Section Brakes Sheet 1 of 1 Date August 1961 SELF ADJUSTING HANDBRAKES Models affected Commencing Chassis Numbers R H Drive L H Drive 2 4 litre Mark 2 108998 126479 3 4 litre Mark 2 156343 177360 38 8 litre Mark 2 205833 217696 On cars with the above chassis numbers and onwards self adjusting handbrakes are fitted The self adjusting mechanism An at therear calipers and takes the place of the handbrake operating lever the operating mechanism is protected by a dust cover plate The adjustment of the handbrakes occurs automatically as the linings wear and is effected by a spring loaded pawl rotating a toothed nut on the adjusting bolt when the handbrake off clearance between the disc and the linings is in excess of a total of 006 15 mm One tooth movement of the rachet nut is the equivalent of 0015 04 mm movement of the lininga Setting the Handbrakes If a rear caliper has been removed from the car or if new handbrake friction linings have been fitted carry out the following procedure With the retaining split pin removed from the screwdriver slot in the adjusting bolt screw the bolt in or out until there is a distance of 7 16 11 1 mm between the friction linings that is the thickness of the disc plus 1 16th 1 5 mm Refit the split pin through the screwdriver slot in the head of
52. the Mintex M 33 pads are as follows Zak litre 3 4 litre Mark 1X XK 150 Friction pads 8 off 1937 e Friction pads front 4 off 7936 rear 4 off 7937 The chassis numbers at which Mintex M 33 pads were introduced are as follows the XK 150 chassis numbers will be advised at a later date Model Commencing Chassis Numbers R H Drive L H Drive 2 4 litre disc wheels 914891 943531 wire wheels 915136 943568 3 4 litre disc wheels 977498 992317 f wire wheels 977791 992531 Mark 1X 771535 790835 XK 150 Open 2 seater Drop Head Coupe Fixed Head Coupe Jaguar Cars Limited 2005 JAGUAR Number L 3 Section Brakes Sheet 1 of 1 Date March 1960 HANDBRAKE CONNECTING LINK Models affected Commencing Chassis numbers R H Drive L H Drive XK 150 Drop Head Coupe 827510 Fixed Head Coupe 836724 On cars with the above chassis numbers and onwards a longer handbrake connecting link is fitted to improve the efficiency of the handbrake The connecting link has two holes at its lower end and for maximm efficiency the pin securing Che Link to the handbrake cross shaft lever must be inserted in the lower hole The new connecting link Part number C 16866 may be Used to replace the previous link Part number C 8316 on cars prior to the above chassis mumbers VACUUM CYLINDER LUBRICANT Models affected Cars fitted with a Lockheed servo The vacuum cylinder oil Cosmolubic 100 recommended for lub ricat
53. til the ratchet ceases to operate which will indicate that the correct adjustment has been obtained With the handbrake applied reasonably hard tighten the pivot bolts and secure with the tab washer NOTE It is ESSENTIAL that the brass retraction fingers are in good condition i e not badly distorted The ends which fit into the pad carriers must be inserted fully into the holes to avoid the possibility of twisting the fingers Aeont ds sees Jaguar Cars Limited 2005 REFITTING THE HANDBRAKE ASSEMBLY AFTER PAD RENEWAL With the friction pad carriers removed withdraw the old pads by slackening the nuts in the outer face of each carrier and utilizing a hooked tool in the hole of each pad securing plate Fit new pads short face upwards ensuring that each pad locates the head of the retaining bolt Fit new retraction fingers and assemble the carrier to the main calipers leaving the pivot bolts slack Pull and release the handbrake lever repeatedly until the ratchet ceases to operate which will indicate that the correct adjustment has been obtained With the handbrake applied reasonably hard tighten the pivot bolts and secure with the tab washer Note It is recommended that new retraction fingers are fitted when _replacing the handbrake pads but they should on no account be bent to suit the calipers Reconnect the handbrake compensator linkage to the operating levers and check the handbrake cable adjustment
54. tion for some reason Jaguar Cars Limited 2005 Ps AAA NOTE Use light pressure only approximately 10 lbs 4 5 kg pedal effort If unbedded pads are fitted clearance may not be measurable but disc should turn reasonably freely by hand Lack of retraction may be due to a Pads sticking in caliper b Wheel cylinder pistons sticking in cylinder or guide location for backing plate c Disc float due to excess end float in front hub bearings or axle shaft as case may be d Disc run out due to machining of mounting flange or disc dirt between faces bent half shaft etc e Sticking master cylinder piston affecting front rear or all main pads depending on model Remedial Action a Remove pads check for any corrosion or dirt build up and that backing plate has been properly engaged with button on piston Check for undue marking on pad due to pressure by retaining clip Clean up all side faces of pads and refit b If retraction is still not satisfactory remove calipers thoroughly clean oft corrosion and acecumulated dirt but do not use abrasive which would destroy cadmium plating On Seri se2 brakes fit wheely cylinder assemblies incorporating recess around pad mounting button on piston _If satisfactory retraction is not obtained fit new caliper body using new wheel cylinder assemblies already on hand c Rectify end float condition in accordance with limits laid down in Service Manual 4 If e
55. vision Part numbers of the Service Kits are listed in the relevant Spare Parts Catalogues whist procedure for the overhaul of these units is fully described in applicable Service Manuals Jaguar Cars Limited 2005 JAGUAR Number L 68 Section Brakes Page 1 of 1 Date October 1970 LOCKHEED BRAKE VACUUM SERVO UNIT Models affected 2 4 3 4 litre Mark 1 2 4 3 4 3 8 litre Mark 2 240 340 Brake S rvo units fitted to the above_models are no longer supplied by Messrs Automotive Products Ltd on an exchange basis and the exchange scheme operated by Jaguar Cars Ltd therefore ceases forthwith It wili be necessary for Servo units to be overhauled by Distributors and Dealers for which purpose a compre hensive range of Service Kits are avajlable from Jaguar Spares Division Part numbers of the Service Kits are listed in the relevant Spare Parts Catalogues whist procedure for the overhaul of these units is fully described in applicable Service Manuals Jaguar Cars Limited 2005 JAGUAR Number L 2 Section Brakes Sheet 1 of 1 Date March 1960 MINTEX M 33 BRAKE PADS Models affected All disc brake cars with quick changes pads In future only Mintex M 33 friction pads will be supplied from the Jaguar Spares Department for replacement purposes These pads are interchangeable with the Ferodo DS 5 quick change pads fitted to earlier cars but they must not be mixed when fitted to an individual car The part numbers of
56. xcessive run out exists check hub flange face output flange face or for bent axle shaft as applicable and if satisfactory replace disc and re check e Check for sluggish return of master cylinder piston if evident service with appropriate repair kit providing cylinder bore is satisfactory SECTION B Symptom Running squeal or intermittent squeal when cornering Remedial Action 1 Check that handbrake operating system is free and permits full return of handbrake Note on Mark 2 cars the axle should be supporting the car to enable adjustment state to be checked 2 Check end float of rear discs 3 Check for oil contamination of handbrake 4 Check adjuster mechanism for free movement and freedom from corrosion 5 Re adjust handbrake mechanism in accordance with insta gmited 2005 in Service Bulletin No L 21 JAGUAR Number L 68 Section Brakes Page 1 of 1 Date October 1970 LOCKHEED BRAKE VACUUM SERVO UNIT Models affected 2 4 3 4 litre Mark 1 2 4 3 4 3 8 litre Mark 2 240 340 Brake S rvo units fitted to the above_models are no longer supplied by Messrs Automotive Products Ltd on an exchange basis and the exchange scheme operated by Jaguar Cars Ltd therefore ceases forthwith It wili be necessary for Servo units to be overhauled by Distributors and Dealers for which purpose a compre hensive range of Service Kits are avajlable from Jaguar Spares Division Part numbers of the Service Kits are

Service 3.4 L - Terry`s Jaguar Parts

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