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[Oddball]

Hey guys. For the most part the shed is running fine. One thing that still bugs me is those brakes. I've tried to get the caliper off the disk, but the rotors are quite worn and I just can't seem to get the caliper off. The pads are getting caught on the lip of the rotor (that little lip that's created once it starts to wear). Is it possible to use brute force to pull it off without damaging the pads, or do I have to push the cylinder back in?

It's really getting on my tits now, i'm getting an ever growing feeling of impending wallet catastrophe. Just started a new job as well, so I really don't have the cash to throw at it.

[Bubba]

rebuild kits are cheap from lightys but yup you got to get the piston back you could linish the lip off wh ith a grinder






woof woof that my other dog impersonation

[JamesH]

Push the piston back in to get the caliper off.

I'd suggest checking the seals around the pistons and probably replacing with a rebuild kit from Lighthouse if needed. Also check for any wear marks (little notches / dents) where the pads locate and slide on the steering knuckle. Often they wear little notches into the metal and this causes them to bind and generally not function properly. You can fill the worn areas with weld and grind smooth - for best welding you should pre-heat the knuckle as it's cast steel but it's not a structural thing you're fixing.

I'd also get new discs and pads from your description.

After all this it'll be as good as new  

[Oddball]

Why don't you knock it off with them negative waves!

Thanks man, i'll try and get the piston back in. Time to get me my hammer!

[Jeepthang]

Why don't you knock it off with them negative waves!

Thanks man, i'll try and get the piston back in. Time to get me my hammer!

I presume you are not using a hammer to get the piston in?  Use a G-Clamp!

[Oddball]

Lol, nah, just kidding about the hammer. Although I do wonder what the missus' response would be.

"Where are you going with the hammer honey?"

"Oh, just off to 'fix' the jeep."

[Dave69]

grind the lip off the disk with an angle grinder then slide the caliper off. get a rebuild kit from lighthouse (£15 approx for the piston and seals) fit the dust seal to the piston first and lubricate it with brake fluid. put it all back together with new disks and pads.

[Oddball]

Righty, got a pair of refurb kits from lighthouse, and a new set of disks and pads too. Should be etting delivered monday or tuesday. I'll let you know how it goes.

Also got the haynes XJ repair manual ('84-'01) off amazon. Don't know how useful it'll be, as apparently diesel engines aren't covered, but a lot of the chassis and suspension components seem to be the same for all models.

Any other manuals or books I should pick up? I noticed halfrauds have a '93-'96 petrol XJ haynes manual, any good?

[PtP]

.......Any other manuals or books I should pick up? I noticed halfrauds have a '93-'96 petrol XJ haynes manual, any good?

Take a look at these two links, they should tell you all you need to know!

viewtopic.php?f=37&t=9334

http://www.stu-offroad.com/suspension/f ... akes-1.htm

Also, don't forget:

..................The mounting bolts are NOT to be torqued too tight.  My factory service manual states 11 ft. lbs.  (Yes...that is NOT very tight at all)...............

[Dave69]

the haynes manual does help for the genreal bodywork etc and most of the suspension but it is useless for electrical, engine and driveline. have a look on ebay as diesel manuals do appera for sale on there. sometimes on cd but there is a manual which is blue and white in colour. price is obviously dictated by demand

[Oddball]

Thanks guy's, i'll keep a look out.

[dxmedia]

Thin screwdriver between the pad and the disk and use the taper on the screw driver to push the piston back into the cylinder. No need for hammers   You best be putting new disks on whilst your in there.

Not a fan of using a grinder on disks in situations like this since if you don't know how to get a caliper off your best not taking a guess at if the disk is within tollerances. Brakes are one thing you don't skimp on IMO.

[Oddball]

Yeah I agree DX, set of refurb kits are on the way along with new disks and pads.