How to Fix an Emergency Brake Cable on 1989 Jaguar XJS V12

The 1989 jaguar XJS V12 emergency braking system is composed of a series of cables and linkages operating independently from the vehicles hydraulic system. This system is designed to slow or stop the vehicle if the primary brakes fail; its secondary function is to secure the parked vehicle or to hold the vehicle stationary on an incline without depressing the brake pedal. Since brake pad wear and slight stretching causes the cables to slacken, the cables must be be adjusted from time to time. If you notice any sign of corrosion or wear, replace the cables as soon as possible.

Instructions

Raising the Vehicle

1

Slide a hydraulic jack rated for at least 5 tons, directly under the mid-point of the forward crossmember.

2

Place a wooden block between the jack head and crossmember. Lift the vehicle to the required height and lower it onto the forward axle stands. Repeat this procedure by

3

Raisie the rear of the vehicle by the mid-point of the aft crossmember, using the hydraulic jack. Lower the rear of the vehicle onto the remaining axle stands.

Front Cable

4

Disconnect the front cable from the forward end where it attaches to the handbrake lever by removing the cotter pin, washer and clevis pin, using pliers.

5

Follow the cable back to the transverse adjuster lever. Disconnect the cable by removing the cotter pin, washer and clevis pin.

6

Smear a dab of axle grease on the clevis pins and fulcrum point of the transverse adjuster lever.

7

Install the new cable onto the handbrake and transverse adjuster levers, using new cotter pins.

Intermediate Cable

8

Disconnect the intermediate cable by removing the cotter pin, washer and clevis pin from the forward transverse adjusting lever, using pliers.

9

Remove the cotter pin, washer and clevis pin on the other end of the cable. Remove the cable from the rear cable transverse yoke.

10

Lubricate the front clevis pin with a smear of grease, replace the cotter pin with a new one and reconnect the cable.

Rear Cable

11

Disconnect the ends of the rear cable from the handbrake assembly on both rear wheels. The cable is tucked behind the backing plate on the underside of the handbrake assembly carrier, and the clevis pins are secured to each handbrake assembly by cable retaining clips.

12

Disconnect both ends of the cable by levering the retaining clips sideways with a thin flat-head screwdriver, then remove the clevis pins.

13

Pull the old cable through the slot in the rear transverse yolk and discard it.

14

Lubricate the groove on the cable transverse yoke with a smear of grease and thread the replacement rear cable through the slot on the yolk.

15

Connect both ends of the cable to the right and left handbrake assemblies by reversing the procedure carried out in Step 2 and securing the clevis pins by rotating the cable retaining clips back into place.

16

Pull the loose transverse yolk forward and reconnect it to the rear end of the loose intermediate cable. Lubricate and replace the clevis pin, washer and cotter pin; be sure to use a new cotter pin.

Emergency Brake Adjustment.

17

Reach inside the vehicle and slowly apply the handbrake while counting the number of clicks coming from the base of the lever. The lever should be fully applied within three to five clicks. If not, adjust the handbrake as follows:

18

Loosen the locknut situated on the end of the cable closest to the handbrake lever with a pair of 3/16 open ended wrenches. Remove all slack from the cable by slowly tightening the cable adjuster nut without going too far and activating the handbrake. Brace the cable adjuster with one wrench and tighten the locknut with the other.

19

Rotate each wheel in turn to ensure that they move freely. If you feel or hear the brakes binding, undo the locknut, loosen the cable adjuster nut a quarter turn and re-tighten the locknut.

20

Lower the vehicle and apply the handbrake while counting the clicks. If the lever is not fully applied within three to five clicks, raise the vehicle back onto the axle stands and readjust as necessary.

21

Drive the car onto a stretch of road that has an incline. Pull over to the side and apply the handbrake to ensure that the emergency brake holds the vehicle steady without it creeping forward.