B. Measuring Circlip

Perform this action on all vehicles within the affected VIN range that have not been excluded by the initial check of the serial no. of the final drive unit.

In additional to normal workshop hand tools, the following is required:

Jaguar special tool ref: JD 231 XK8 fuel injector- remover

This tool is used as a gap gauge during the following procedure.

1. Place the vehicle on a lift; loosen but do not remove, the retaining nuts of both rear wheels. Leave the vehicle with the handbrake released and "N" selected.

2. Partly raise the vehicle.

3. Remove the rear wheels; fully raise the lift.

4. From one side of the vehicle, remove the brake caliper retaining spring.

5. Remove the covers from the hex-head guide pins and remove the guide pins.

6. Pull out the caliper from the carrier and remove the brake pads.

7. Support the caliper, using string or wire to suspend it from the road spring to avoid strain on the brake hydraulic hose, which should not be disconnected.

8. Mark the alignment of each axle shaft flange to the final drive unit output flange, so that the original alignment is kept during reassembly.

9. Wipe the nuts and the ends of the drive flange studs clean, and lightly oil or grease the ends of the threads. Remove and discard the four lock nuts that retain the axle shaft coupling flange to the final drive unit output flange. It will be necessary to position a bar between the wheel studs to prevent rotation of the axle shaft when loosening axle shaft lock nuts.

Note:
That with the rear suspension hanging free, the axle shaft is in tension, and the flanges will separate as the nuts are loosened.

10. Carefully disengage the axle shaft from the studs of the output flange. Ensure that the faces of the flanges are kept parallel to each other as the shaft flange comes off the studs, to avoid damage to the stud threads. Remove the camber adjustment shim. The top of the hub carrier will lean outwards. Use string or wire, attached to the road spring, to support the hub carrier, ensuring that the handbrake cable is not under tension.

Note:
Before proceeding further, carefully examine the condition of each stud thread of the drive shaft flange, particularly if it was difficult to remove one or more of the lock nuts.

These lock nuts have distorted threads at their outer end to provide the locking action. Occasionally, tearing of the stud thread may occur as a nut is removed. Check that a new nut can be installed by 2-3 turns on each stud before proceeding further.

If thread damage has occurred and can not be easily rectified in place, or if there is stud damage for any other reason, skip the checking procedure in steps 11-24 below for the affected shaft. Remove the shaft and bearing assembly, as described under repair procedure stage 2. Replace the damaged stud(s) while the shaft is off the vehicle.





11. Rotate the final drive output flange until both ears of the circlip shown in Illustration 1 become visible and accessible. Note that the circlip may have been installed in different position than illustrated.





12. Attempt to insert the tip of the special tool between the ears of the circlip as shown in Illustration 2.

13. If the tip of the tool fits between the ears, so that the whole width of the tool is in contact with the face of the bearing, the circlip is seated adequately.

The width of the tool is approximately 9.65 mm. A gap between the circlip ears of up to approximately 18 mm may be measured.

Note:
The tool must fit between the ears of the circlip.

14. Repeat steps 4-13 on the opposite side of the vehicle.

15. If circlips are properly seated on both sides of the vehicle, clean the drive flange stud threads and reassemble the axle shafts using new lock nuts, in the reverse order of disassembly. Do not lubricate the threads of the studs since the replacement nuts have a self-lubricating finish.

WARNING:
Do not reuse the original nuts.

Drive coupling nuts:

torque specification: 90 Nm (66 lb ft)

Brake caliper guide pins:

torque specification: 28 Nm (21 lb ft)

16. If the circlips on one or both sides have too small a gap, proceed through those sections of the proper repair procedure as needed to correct the condition.