1998 JAGUAR X308 Suspension

oc
curs only with the parking brake, th
e concern is in the rear brake system.
If the concern becomes evident during this check, verify it fits the description given before the road test. If the concern is
not evident, attempt to duplicate the condition using the information from the description.
If a concern exists, use the Symptom Chart in order to isolate it to a specific sub-system and condition description. From
this description, a list of possible sources can be used to further narrow the cause to a specific component or condition.
Sym
ptom Chart
Sy
m
ptom
Possib
l
e Sources
Acti
o
n
Brakes
n
oisy
Brake pads.
Brake di
scs
.
*
*
GO to Pinpoint
Tes
t A.
*
Vibration wh
en brakes
are applied
Wh eels require bala
ncing.
Wheel hub nuts.
Caliper mounting bolts.
Brake pads.
Foreign material/scr atches/corrosion
on brake disc contact surfaces. Excessive brake disc thickness
variation. Excessive brake disc runout.
Wheel bearing wear or failure.
Suspension bush wear or failure.
Steering bush wear or failure.
*
*
*
*
*
*
*
*
*
*
Go to Pinpoint
Tes
t B.
*
The brakes pull or drif tTire pressures/wear.
Calipers.
Brake pads.
Brake di
scs.
Wheel alignment adjustment.
Wheel bearing.
Suspension bushes and ball joints.
*
*
*
*
*
*
*
GO to Pinpoint
Tes
t C.
*
The pedal feels spongyAir i
n brake system.
Leak in hydraulic system.
Brake booster/master cylinder.
Brake pads.
*
*
*
*
GO to Pinpoint Tes
t D.
*
The pedal goes down
fa s
t
Ai
r i
n brake system.
Leak in hydraulic system.
Brake booster/master cylinder.
Brake pads.
*
*
*
*
GO to Pinpoint
Tes
t E.
*
The pedal goes down
slowl yAir i
n brake system.
Brake booster/master cylinder.
*
*
Go to Pinpoint
Tes
t F.
*
Excessive brake pedal
effor tBrake pads.
Brake booster.
*
*GO to Pinpoint
Tes
t G.
*
Brake lockup du ring ligh
t

brake pedal force
Brake pads.
Calipers.
*
*GO to Pinpoint
Tes
t H.
*
Brakes d r
ag
Parkin
g brake con
trol
applied/malfunction. Seized parking brake cables.
Seized caliper slide pins.
Seized caliper.
Brake booster.
Pedal gear.
*
*
*
*
*
*
GO to Pinpoint
Tes
t I.
*
Exce ssi
ve/Erratic brake
pedal travel
Hydrau li
c system.
Brake pads.
Brake discs.
Hub and bearing assembly.
*
*
*
*
GO to Pinpoint
Tes
t J.
*
The red brak e warning
indi
cator is always on
Fl
ui
d level.
*
F I
LL the system to specification. CHECK for leaks.
*
Brake flu i
d level sensor.
*
I N
STALL a new brake master cylinder fluid
reservoir. For additional in formation, refer toSection
206
-0 6
Hydraulic Brake Actuation
.
*
Parkin
g brake con
trol.
*
REL
E
ASE and ADJUST the parking brake. For
additional information, refer toSection 206
-05
Parkin g Brake an
d Actuation
.
*
E
l
ectrical circuit.
*
F or additional
information, refer to PDU for
analysis/rectification of the concern.
*
Sl
ow or i
ncomplete brake

Brake peda
l binding.
*
GO to Pinpoint Tes
t K.
*

pedal retu rnBr
ake booster/master cylinder.
*

P
INPOINT TEST A : BRAKES NOISY
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
A1

: INSPECT BRAKE PADS
Inspect the condi

tion of the front and rear brake
pads. Check for damage to any anti-squeal shims.
1
Are th
e brake pads OK?
Yes GO to A2
.
No

CLEAN the front brake pads or INSTALL new front brak e pads if necessary. For additional information,
refer toSection 206
-03
Front Disc Brake
. CLEA
N the rear brake pads or INSTALL new rear brake pads
if necessary. For additional information, refer toSection 206
-0
4 Rear Disc Brake
.
Test vehicle for
presence of brake squeal.
A2
: INSPECT BRAKE DISCS
Inspe

ct the brake discs for excessive corrosi
on, wear or disc thickness variation.
1
D
oes excessive corrosion, wear or
disc thickness variation exist?
REFER to Specification
- in t
his section.
Yes INSTALL new front brake discs and brake pads. For additional information, refer toSection 206
-03

Fr

ont Disc Brake
. INSTALL n
ew rear brake discs and brake
pads. For additional information, refer
toSection 206
-0
4 Rear Disc Brake
. TEST
the system for normal operation.
No Vehicle is OK.
P
INPOINT TEST B : VIBRATIO
N WHEN BRAKES ARE APPLIED
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
B1

: ROAD TEST VEHICLE
R

oad test the vehicle between 40-80 km/h (25-50 mph) without applying brakes.
1
Is th

e vibration present?
Yes TEST for noise vibration and harshness. REPEAT road test if necessary.
No GO to B2
. .

B2

: CHECK FOR BRAKE VIBRATION
R

oad test the vehicle between 40-80 km/h (25-50
mph) with light and medium application on the
brake pedal.
1
Is a vibration
present?
Yes If the vibration is from the front of the vehicle GO to B3
. If
the vibration is
from the rear of the
vehicle or can not be di agnosed between front or rear of the vehicle GO to B6
.
No

Vehicle is OK.
B3: CHECK
THE SUSPENSION
AND STEERING COMPONENTS
Chec
k the condition of the front susp
ension bushes and ball joints
REFER to Section 204
-01
Front Suspension
.
Chec
k the condition of the steering linkage components
REFER to Section 211
-0
2 Power Steering
/

211
-0
3 Steering Linkage
.
1
D

o any of the front suspension components or steering comp
onents require replacement?
Yes INSTALL new components as necessary
REFER to Section 204
-01
Front Suspension
/

211
-0
2 Power Steering
/

211
-0
3 Steering Linkage
.
R
oad test the vehicle between 40-80 km/h (25-50
mph) with light and medium application on the
brake pedal. If vibr ation still exists GO to B4
.
No

GO to B4
.
B4: CHECK
THE FRONT BRAKE PA
DS AND FRONT BRAKE DISCS
Chec
k the condition of the front br
ake pads and front brake discs.
1
D
oes excessive brake disc runout or br
ake disc thickness variation exist?

REFE
R to
Specification
- /
F r
ont Brake Disc Runout Check
- V
eh
icles With: Brembo Brakes
/

F
ront Brake Disc Runout Check
- V
e
hicles Without: Brembo Brakes

in this
section.
Yes GO to B5
.
No
GO to B6
.
B5: CHECK VEHICLE
FOR A HISTORY OF BRAKE VIBRATION PROBLEMS
Chec
k to se
e if the vehicle has recently been
repaired for brake vibration problems by the
installation of new front brake discs and pads.
1
Has vehicl
e has recently been repaired for brake vibrat
ion problems by the installation of new front brake
discs and pads.
Yes INSTALL new front wheel hubs
REFER to Section 204
-01 Fron
t Suspension
.
INST ALL new fr
ont brake disc
s and front brake pads
REFER to Section 206
-03 Fr
ont Disc Brake
.
TEST the system for normal
operation.
No INSTALL front brake discs and front brake pads
REFER to Section 206
-03 Fr
ont Disc Brake
.
CHECK for excessiv
e brake disc runout
REFER to Front Brake Disc Runout Check
- Veh
icles With: Brembo Brakes
/

F
ront Brake Disc Runout Check
- V
e
hicles Without: Brembo Brakes

in this
section.
If excessive brake disc runout exis ts INSTALL new front wheel hubs
REFER to Section 204
-01 Fron
t Suspension
.
TEST the system for normal
operation.
B
6:
CHECK THE REAR BRAKE PADS AND REAR BRAKE DISCS
Chec
k
the condition of the rear brake pads and rear brake discs.
1
D
o
es excessive brake disc runout or br
ake disc thickness variation exist?
REFER to Specification
- /
Rear B
rake Disc Runout Check
- Ve
hicles Without: Brembo Brakes
/
Rear
Brake Disc Runout Check
- Veh
icles With: Brembo Brakes
in this
section.
Yes INSTALL rear brake discs and rear brake pads
REFER to Section 206
-04
Rear Disc Brake
.
CHECK for excessiv
e brake disc runout.
REFER to Rear Brake Disc Runout Check
- Veh
icles With: Brembo Brakes
/

Rear
Brake Disc Runout Check
- V
e
hicles Without: Brembo Brakes

in this
section.
If excessive brake disc runout exists INSTALL ne w rear wheel hubs. TEST the system for normal
operation.
No REPEAT road test and re-check for a vi bration concern. If vibration exists GO to B3
.
PINPOINT TEST
C : THE BRAKES PULL OR DRIFT
TE
S
T
CONDITIONS
D E
TAILS/RESULTS/ACTIONS
C1
:
ROAD TEST VEHICLE
Road test th
e veh
icle and apply the brake pedal.
1
D
o
es the vehicle pull or drift?
Yes GO to C2
.
No
Vehicle is OK.

C2:
INS
PECT TIRE PRESSURE
Check f
or ex
cessive tire wear
or incorrect pressures.
1
Are the ti
res at the correct pressure and in good condition?
Yes GO to C3
.
No
AD
JUST the tire pressures or IN
STALL new tires if excessively wo rn. TEST the system for normal
operation.
C3 : CH
ECK CALIPERS
Check the fr
on
t caliper pistons for binding, leakin
g or sticking. For additional information, refer
toSection 206
-03 Fr
ont Disc Brake
. Check the rear cal
i
per pistons for
binding, leaking or sticking. For
additional information, refer toSection 206
-04
Rear Disc Brake
.
1

Do t
he disc brake caliper pistons
and pins bind, leak or stick?
Yes INSTALL new calipers as necessary. TE ST the system for normal operation.
No GO to C4
.
C4: INSPECT BR
AKE DISCS
Check the brake discs fo

r excess
ive damage, thickness variatio n or runout. For additional
information, refer to General Procedures in this section.
1
D
oes excessive damage or runout exist?
Yes INSTALL new brake discs and brak e pads as necessary. TEST the system for normal operation.
No GO to C5
.
C5: INSPECT THE FRONT HU
B AND WHEEL BEARING ASSEMBLY
Check the fr

ont hub and wheel bearing assembly.
For additional information, refer toSection 204
-00

Su

spension System
- General
Information
. 1
Are th

e wheel bearings OK?
Yes GO to C6
.
No

INSTALL new wheel bearings. For additional inform ation, refer toSection 204
-01
Front Suspension
.
TEST the system
for normal operation.
C

6: CHECK SUSPENSION BUSHES AND BALL JOINTS.
Chec

k all suspension bu
shes and ball joints.
1
Are th
e suspension bushes and ball joints OK?
Yes Vehicle is OK.
No INSTALL new front suspension bushes and ball joints as required. For additional information, refer
toSection 204
-01
Front Suspension
. INSTALL n
ew rear suspension bush
es and ball joints as required.
For additional informat ion, refer toSection 204
-0
2 Rear Suspension
.
P

INPOINT TEST D : THE PEDAL FEELS SPONGY
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
D

1: CHECK FOR SPONGY PEDAL (ENGINE OFF)
Check f

or a firm brake pedal.
1
Is th

e brake pedal effort an
d brake pedal travel normal?
Yes Vehicle is OK.
No GO to D2
.
D2:
CHECK BRAKE PEDAL RESERVE (ENGINE OFF)
Pump th

e brake pedal 10 times and
hold on the final application.
1
Does th
e brake pedal feel fi
rm on final application?
Yes GO to D3
.
No

BLEED the brake system. For additional information, re fer to General Procedures in this section. TEST
the system for normal operation.
D3:
CHECK BRAKE PEDAL RESERVE (ENGINE ON)
Engine is

idle.
1
Apply the brake pedal ligh

tl
y three or four times.
2
W
ait 15 seconds for the vacuum to recover.
3
Push down on

the brake pedal until it stops moving
downward or an increased resistance to the brake
pedal travel occurs.
4
Hol
d the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
5
Re

lease the accelerator pedal.
6
Does th

e brake pedal move downward as
the engine speed returns to idle?
Yes GO to D4
.
No

CHECK the vacuum to brake booster. For additional information, refer toSection 206
-0
7 Power Brake
Actuation.

Yes

Vehicle is OK.
No GO to J2
.
J
2: CHECK BRAKE FLUID LEVEL
Check the brake master cyli

nder reservoir fluid level.
1
Is the fl

uid level OK?
Yes GO to J3
.
No

CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake
Master Cylinder in this section. ADD brake fl uid and BLEED the brake system. For additional
information, refer to General Proc edures in this section. TEST the system for normal operation.
REPEAT road test if necessary.
J
3: CHECK BRAKE PEDAL RESERVE
Engine is

idle.
1
Apply the brake pedal ligh

tl
y three or four times.
2
W
ait 15 seconds for the vacuum to replenish.
3
Push down on

the brake pedal until it stops moving
downward or an increased resistance to the brake
pedal travel occurs.
4
Hol
d the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
5
Re

lease the accelerator pedal.
6
Does th

e brake pedal move downward as
the engine speed returns to idle?
Yes GO to J4
.
No

CHECK the vacuum to the brake booster. Fo r additional information, refer toSection 206
-0
7 Power
Brake Ac

tuation
.
J

4: CHECK THE FRONT HUB AND BEARING ASSEMBLY
Check the fr

ont hub and bearing assembly. Fo
r additional information, refer toSection 204
-01
Front
Suspe

nsion
. 1
Are th

e front wheel bearings loose?
Yes INSTALL a new front wheel bearin g if damaged. For additional information, refer toSection 204
-01

F

ront Suspension
. TEST
the system for normal operation.
No CHECK the front brake discs for thickness variances. For additional information, refer to General
Procedures in this section.
PINPO
INT TEST K : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
K1: C

HECK FOR BRAKE PEDAL RETURN
Ru

n the engine at fast idle while
making several brake applications.
1
Pull the
brake pedal rearward with approximately 44.5 N (10lb) force.
2
Relea

se the brake pedal and measure
the distance to the toe board.
3
Make a hard brake
application.
4
Relea

se the brake pedal and measure the brake
pedal to toe board distance. The brake pedal
should return to its original position.
5
Does th
e brake pedal return
to its original position?
Yes Vehicle is OK.
No GO to K2
.
K
2: CHECK FOR BRAKE PEDAL BINDING
Check the brake pedal to make
s
ure it is operating freely.
1
Is th

e brake pedal operating freely?
Yes INSTALL a new brake booster. For addi tional information, refer toSection 206
-0
7 Power Brake
Actuation. TEST

the system for normal operation.
No REPAIR or INSTALL new brake pedal. TE ST the system for normal operation.

2.
Remove paper backing from pads to reveal adhesive
shim. Install brake pads, insert clip located on back of
inner pad into caliper piston.

3. Inst al
l caliper housing to caliper carrier.
Align hou
s
ing to carrier.
1. Install and tighten guide pins to 25-30 Nm.
2. Install dust covers.
3. Install anti-rattle spring.

4. NOTE : Th
e brake hose must only be installed with the vehicle's
body supported and the suspension hanging.
Install and tighten brake hose to caliper housing to 10-14 Nm.

5. NO
TE: Make sure the brake
hose does not twist when
tightening the hose lock-nut.
Connect brake hose to brake tube.
1. Position hose thread through bracket.
2. Install and tighten locking nut. Refer to Specifications, section 206-03.
3. Install and tighten brake- tube union nut. Refer to
Specifications, section 206-03.
6. Remove special tool from brake pedal.
7. Fit wheels. Refer to section 204-04.
8. NOTE: Make sure the brake hose is routed correctly.
Remove stands and lower vehicl e. Refer to section 100-02.
9. Bleed brake hydraulic system. See operation 70.25.03.

2.
Po
sition anti-rattle spring.
3. Install pins.
4. Install 'R' clips.

3. CAUTIO
N: The brake hose must
only be installed with the
vehicle's body supported and the suspension hanging.
Install brake hose to caliper.
Remove plugs f rom caliper and hose.
Instal
l new sealing washers.
Install and tigh
ten un
ion bolt to 22-26 Nm.

4.
NO
TE: Make sure the brake
hose does not twist when
tightening the hose lock-nut.
Connect brake hose to brake tube. 1. Position hose thread through bracket.
2. Install and tighten locking nut. Refer to Specifications, section 206-03.
3. Install and tighten brake- tube union nut. Refer to
Specifications, section 206-03.
5. Remove special tool from brake pedal.
6. Fit wheels. Refer to operation 74.20.05.
7. NOTE: Make sure the brake hose is routed correctly.
Remove stands and lower vehicl e. Refer to section 100-02.
8. Bleed brake hydraulic system. See operation 70.25.06.

In
stallation

11
. Remove brake
dust and clean
mating surfaces. See Warning
above.

1. Inst al
l caliper to hub carrier.
Install and tigh
ten bolts to 6
0 Nm.

2. CAUTI O
NS:
Retracting the caliper piston may cause the fluid reservoir
to over-flow. Remove brake flui d spillage immediately from paint
work with clean water.
Note the condition of the pi ns and replace if necessary.
Install brake pads. Refer to 70 .40.09 for anti-squeal grease
application.
Sl owly
retract caliper pistons.
1. Install pads.
2. Position anti-rattle spring.
3. Install pins - make sure pin collets are fully engaged
into caliper.
3. CAUTI O
NS:
The brake hose must only be installed with the vehicle's
body supported and the suspension hanging.
It is important that the brake hose is aligned correctly when