2004 XJR Brembo Brake and Rotor Replacement
 

Well fellow Jaguar owners: I completed my XJR complete brake and rotor replacement. I installed ceremic pads for my brembo brake system, front and rear. I was afraid at first but once I remove the front and rear brakes and pads, the caliper removal was easy. Just the two 13mm caliper boths in the front and two 1/2 caliper bolts for the rears (each caliper).

My troubles came when I had to bleed the brake system. I learned its best to use a clear jar (filled with brake fluid), a clear plastic tube to place over the brake bleeder screw, and a wrench to open up the brake bleeder screws. You need some one sitting in the vehicle to pump the brakes and hold as you open the brake bleeder screw to let out air bubbles in the system as well as debris that has gathered in the system. Its pretty easy once you get started.

Major issue was my electronic parking brake. Because I replaced the rotors the electronic parking brake had to be removed. Two blots to remove, then take a plan pair of needle nose pliers to TURN BACK the piston. But you first have to remove the brake pads,, by removing the retaining pins,, then the brake drop threw. My air suspension got out of wack (air suspension fault error msg) so I disconnected the brake, then reconnected it to reset the system. I followed an earlier posted How To Recalibrate your parking brake and it worked out fine. If you have any experience with brake systems dont be afraid to tackle this type of job. The dealer estimated $2300 to replace regular rotors and pads.. I purchased slotted rotors and ceramic pads for $650.00 , did it myself and saved.

Where did you purchase your pads and rotors?

(I've moved your thread from the X308 section to the X350 section.)

Great result and a big saving.

Graham

Great to see some one has posted about a Brembo pad and rotor replacement, well done on the job. Be prepared to answer questions as we all have a go at this.

I purchased my brake pads from PartsGreek both front and rear for $166.00. I have driven over 500 miles and not one sign of brake dust,,, NONE. And with the dippled slotted brakes the car stops effortlessly. eek

I got my rotors from BrakePerformance. Got them in 4 days. All four for $454.86 that included shipping. I painted my rotors silver and as I said in my earlier response, NO Brake Dust. I am truly impressed with the pads and rotors. It was worth it, price wise. Except for a few anxiety moments, I now have the confidence and experience to do again years from now. Oh yeah, I figured out the Air Suspension Fault and Emergency brake fault problem too. Just disconnect your battery ground cable (in the trunk) for about 30 seconds. Reconnect, drive the vehicle and you should not see either again.

So good luck to those who plan to tackle the job of brake and rotor replacement for 2004 XJRs.

I need to replace the emergency brake pads on my 2004 XJR. can you clarify in a bit more detail about the emergency brake errors and suspension issues before I tackle the project. Disconnect the battery to reset the emergency brake electronics and air suspension errors?

I had suspension issues because I lifted all 4 wheels and one time. But if you are only replacing he emergency brake pads you should get an Air Suspension Fault error code.

If I can be instructed on how to attach a docment I will attach the instructions

You should see the attachment. I copied it from another thread. It worked for me.

Melvin

Melvin

thanks for the attached proceedures. I am always concerned when specific tools are mentioned. Do you have any idea if the electronic box is actually required for an XJR or if is would be nice to have?

any others input would be appreciated

ryejag

Do you have to split the calipers to turn the pistons in?

viper1996
To reset the parking brake rotors on Brembo brakes you need to remove the calipers by removing the two slide pin/mounting bolts. Then the calipers can be reset with needle nose pliers, prior to reinstalling the new parking brake pads. Once installed the Electronic parking brake needs to be recalibrated. No need to split the calipers. Prior to reassembly, I would clean and lube the assembly
RyeJag

On our '04 XJR with Brembo brakes I was not able to use standard needle-nose pliers to adjust the caliper because the outer pad clamping lobes were in the way. I would have had to separate the two halves of the caliper, but the Torx screws were too tight and may have also had thread locker. I would have had to reinstall the caliper in order to apply enough torque to remove the screws. If you have a pair of needle-nose pliers with 90-degree tips that will fit in the caliper holes they may work. I have some dainty ones with 45-degree tips but I couldn't get a grip in the holes secure enough to rotate the caliper.

The solution I came up with was to clamp two machine screws in the jaws of my needle-nose Vise Grips (Mole Grips) and use that assembly like the special Jaguar tool to rotate the piston:

https://cimg1.ibsrv.net/gimg/www.jag...ae8bad7cbe.jpg


Next time I'll probably remove the Torx screws and pull the outer half of the caliper, leaving the inner half in place.

Cheers,

Don

Awesome Thanks!!!

Don B
Looking at your photo of the Brembo Parking brake it is exactly the same as mine and it appears as if there is a missing boot on one of the slides. One side of my electronic parking brake goes through pads every 10K miles but not on the other side. Any clues what to look for? I have cleaned and lubed the slides and do not notice anything unusual. I plan to go thru the recalibration procedure after replacing the pads again.
RyeJag

When replacing the EPB pads you will find the rear rotor is at the end or near to the end of its life. So I always change rotors at the same time as the EPB pads.

The quickest and easiest way is to split the caliper using the 2 torx bolts
I use an old angle grinder nut tool to do the wind back
Assembly is simply insert the first pad then the disk. Now the second half of the EPB with the new pad. Finally the Brembo caliper and pads.

With the calibration, it will fail if you have wound back PB caliper to far.
All you need to do is reset the system. This can be done by a battery disconnect but I prefer to pull the EPB fuse in the boot. This just resets the EPB so you dont have to do things like calibrate the windows as with a battery disconnect

The EPB calibration fails after a few attempts however it does move the pads in (winding out the piston). After that it wont move the piston out any further till you reset the system. This does not apply when using SDD for the calibration but I find using SDD is too slow. Far quicker to remove/replace the EBP fuse

Cheers
34by151

OK, I'm about to replace the rear rotors/pads and epb. (2004 XJR Brembro)

My understanding from reading the threads is as follows:

1. Keep epb release button on console depressed while shutting off the engine (keeps epb released)
2. lift rear end , remove wheels
3. remove two(2) torx screws, remove lateral aspect of epb caliper
4. Remove rear caliper
5. remove rotor
6. retract epb piston clockwise, retract caliper piston (bleed screw loosened protocol when retracting)
7. replace rotor and pads
8. replace wheels
9. pump brake 5-10 times

10. if epb fault code appears: (re: 34by151)
10a. Turn off ign
10b. Remove fuse F32 from the rear fusebox
10c. Cycle engine and replace fuse
10d. Repeat the calibration, you will again hear the epb motor working
10e. 'Rinse and repeat' (repeat steps 10a-10c) until epb is calibrated and error message is gone

Robert Z
I don't understand your comment number 6 bleed screw loosned. There is no bleeder in the EPB.

Ryejag

Addendum to 6:

There is no bleed screw on the epb,...., I was referring to the 'other' caliper
Good catch

You painted the rotors "silver" ?