After my rear brake had seized I finally found time to rip the whole stuff out. The outer brake pad on the right side was completely gone and the carrier plate had scratched the disc. The inside pad was practically new, so the fault had to be somewhere in the sliding mechanism.
Left side seemed to start the same problem, outer pad was substantially thinner than the inside one, but still with enough meat on the bone.
And there are the 2 culprits (the left pin on each, the right ones can be seen to be slightly compressed)


On each side one of the sliding pins is scuffed and doesn't move in or out anymore. The other one is smooth on both sides.
Now my question, Does anyone know a good trick how to get the stuck pins out of the bore?
Brute force?
Wrench? I think a 17mm wrench could be applied to force them to at least turn.
Have fellow members here done the same repair and could the caliper be recovered or should I already make friends with the idea to invest into 2 new ones?

I'll post some more pictures and reports during the progress of my brake overhaul, but to start with I need to break these pins free ...

 

You could try WD40/CRC the heck out of them and put them in the freezer overnight, may be enough to give some more clearance.

 

Managed to get the guiding pins out by holding them in the vice an turn the brake pad holder. Especially the right was really stuck. First losen it by turning, then turn and pull simultaneously until it pops free.
But the parts look like this is not a quick fix by simple "polish and apply new grease".

The two corroded pins look beyond reuse and the corresponding bores the same. Are these sleeves that can be exchanged in the caliper holder?





Does anyone know a good source for these parts? Preferably EU-based?
Oh, and is there a smart way to unhook the park brake cables from the caliper without unbolting the whole mechanism at the back of the piston?

 

Bloody hell! That's impressively bad.

Have you checked on parts prices either from a Jaguar main agent, an independent, or a Jaguar breakers? I wouldn't be surprised if the caliper carriers are a Ford part. Any part numbers on them?

Failing that, what about taking them to a machine shop and having a very small amount bored out of them?

As for the handbrake, I've no idea. Sorry.

 

Does this help?

https://workshop-manuals.com/jaguar/...03)/page_1430/

 

You may try soaking everything in Evaporust (or what you may have in the UK that is similar). That will remove the deposits to show what you have to work with. Although I would probably replace the complete assembly. I imagine the bores on the calipers are pitted as badly as the pins are corroded. Even if you can clean everything up well enough to serve for a bit I would plan on replacement.

I purchased my replacement rotors and pads from Brake Performance and they show replacement calipers with bolts/pins (although I would call to verify they are in stock). They powder coat everything to match. The ones from Rock Auto also appear to be complete. Unfortunately I can can not help with who is in the UK.

 

Absolutely, there was no floating anymore on these calipers. The outer pads were down to the steel carrier on the right side:


The left side also started already with outside pad wear about twice that of the inside pad:



After checking the bores of both carriers a bit closer I gave up on restoring them and looked for new. The amount of pitting would probably have me do the same again in 6 months from now. You can see the inside of the guides in the picture at the beginning of the thread.
After an of evening research, looking for the carrier in the aftermarket, or potentially also just the insert (which actually exists as a separate piece) I decided to bite the bullet and carry my cash to the official Jaguar dealer here.
Official spare part breakdown is that you can get the complete carrier assembly with installed guiding pins, rubber jackets and new bolts. Available overnight and not completely devastating at around 120€ each. Well, I have an idea of the TPC of these cast and machined parts, so that's a really decent profit for Jag, but hey, they gave us this beauty, so they shall make their living
And if I wanted to be cheap at all cost I should drive a Dacia Logan ...

Refering to my post in "what have you done today ...", originally I worried a lot that I wouldn't have space in the garage, but after the wheels are off the working area is quite spacious with the car lifting it's booty towards the door.


The remains look ok, piston on the right (the bad side) could be easily retracted with the proper tool. Curiously the piston on the left (the better side) was very reluctant to return into their housing.

Left:


Right:


Now there is still a lot of brush work left, which I realized I don't have a small enough steel brush to reach into the corners. Is on the purchase list now.
BTW, the colors in the pictures look a lot more reddish and rusty than the original hubs.

After that I'll turn the car around and get to the front. Wish me luck that they don't look as bad. I hope I won't also have to get new carriers for the front ...

 

Thanks for the link, it helps ... sort of.
I haven't set the system into service mode for lack of a proper service software. Will that release the brake cable any further? The handbrake is currently already not engaged (pushed the button while pulling the key).
Besides that, releasign the park brake lever doesn't give enough clearance to pull the noose overe the edge of the lever due to the thick and stiff cable that can't be bent and has very little room to manoeuvre.
So in this regard I'm still stuck and it looks like I'll try to clean the piston part without taking it off the car.

 

To conclude the topic, the cat can stop again.

MTEC was quite fast to deliver the discs, but I didn't envy the poor mailman. The complete set of four discs plus pads was certainly not his easiest delivery of the day, given that you need to walk the last 80m to our house entrance

To get the car back on the road I eventually took the easy way
First I left the stupid hand-brake cable where it was and brushed the piston block (and all the rest of the area) as good as possible with cable and brake hose connected. The whole brake area was covered in brake dust at least 3mm thick, never seen anything like that. I had a real pile of black dust on the garage floor on each side after finishing.



Fitting the new brake carriers, discs and pads was quite easy. Had to take some of the old anti-rattle spings because the new pads came with to few.
When the whole system is in the open like here without wheel the mix of new and shiny brake carrier and old rotten piston block looks a bit shaggy, but with wheels on it doesn't show so clearly





The grooved discs look somewhat more interesting than the plain flat original style. During brake-in they made quite some humming noise, but now after about 500km they only purr a bit when braking hard, which actually sounds quite nice.
When acceleration is allowed to have a pleasant engine sound, deceleration should also be allowed to have a pleasant brake sound.

Now that the technical issues are more or less done I hope I'll have some time to get to my bluetooth streaming project