Electric Park Brake - EPB - swap out - removal and replacement

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iRS
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Electric Park Brake - EPB - swap out - removal and replacement

Postby iRS » Wed Feb 20, 2019 10:53 am

Can anyone on here offer any words of advice on swapping the EPB motor? I can see where it is, but unclear how it disconnects. I seem to have a short on the motor conductors so assume the motor has gone. I have checked the callipers and all good there. Mine has the separate brake callipers so there seems so be a brake cable running from the rear side of the rear subframe to the front side and there it connects to the cables that go to the callipers. I believe on the cars without separate brake callipers, the brake cable runs direct from the motor to the calipers. The manual helpfully instruct to drop the rear sub frame. I'm hoping to avoid that.
Last edited by iRS on Mon Mar 04, 2019 1:13 pm, edited 1 time in total.
Roger S
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Re: Electric Park Brake - EPB - swap out

Postby J44EAG » Wed Feb 20, 2019 1:14 pm

Dropping sub-frame, Roger? At least you have a ramp...useful.

If you do need to drop, ensure you fully Tipex mark up the mounting bolt positions and also at other useful locations before you drop the frame out. There is a huge amount of variation on where it is possible to remount the frame after removal.....Check measure and make a note of the dimensions for wheel base length both sides of the car. As a final check after finishing the job, the resetting those dimensions will act as a confirmation that the frame is back in again correctly. Avoid dropping the frame if you can. Re-alignment is not always easy.

Mike
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PaulGover
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Re: Electric Park Brake - EPB - swap out

Postby PaulGover » Wed Feb 20, 2019 10:21 pm

...
I seem to have a short on the motor conductors so assume the motor has gone.
...
Don't assume that without checking. There are a couple of known problems with the EPB wiring harness: its insulation can abrade where it passes through various metal bits, and there's a splice somewhere in it that can go wrong.

There should be a connector near the motor, under the car, and another under the RH side of the rear passenger seat, under an access cover for the fuel tank; then it goes off to a control module behind the RH side of the boot lining. That's for facelift cars like mine; things may be a bit different on others.
1981 XJ6 Series III basket case
1991 XJS V12 "facelift"
2008 XJ TDVi

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iRS
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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby iRS » Mon Mar 04, 2019 1:16 pm

Thanks guys for both your suggestions.

I am making no progress so far. I tried lowering the diff a little, but still can't remove the old one. Still trying.

I can see why the wiring gets damaged sometimes. There's a connector above the n/s drive shaft and I suspect if this drops out of place the wiring then comes into contact with the drive shaft.

I shall continue and then post some photos.
Roger S
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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby J44EAG » Mon Mar 04, 2019 11:18 pm

You are a brave type tackling this job mid winter, Roger!

We will all be interested to see how this pans out. Fortunately, this aspect of the car seems to give only infrequent issues.

Mike
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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby iRS » Tue Mar 05, 2019 11:05 pm

I've just got the old one out. What a battle. It took me hours. It just seemed to find a million ways fo jamming it self in. A crow bar to pull the diff out the way helped a little. Finally it came out. Tomorrow I'll see about getting the replacement in........
Roger S
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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby J44EAG » Tue Mar 05, 2019 11:18 pm

Phew! I can feel the pain.

I could and did do this type of thing myself fifteen years ago. Then I did it once too often and wrecked my lower lumbar for ever.

Don`t strain yourself, Roger. It is never worth it.

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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby iRS » Tue Mar 12, 2019 9:53 am

I finally got this job completed over the weekend. It was one of the most fiddly and frustrating jobs I have done. My recommendation would be that if you need to do this job, take your car to a good specialist who has done it before and is confident they can do the job again in a few hours. If you try it yourself make sure you have good access to the underside, ideally a vehicle lift. I couldn't imagine doing the job lying on my back underneath the car. I found there were many sticking points. Most of which I got to and couldn't see how to get past them, then miraculously somehow I did.

These are:
Getting to and undoing the rear diff bolts - I cut down an 18mm socket
disattaching the passenger side cable from the link piece
disattaching the end of the actuator cable from the cable to the driver's side - there's a u shaped piece of metal that links the two
manipulating the actuator out of its position to the passenger side
getting the replacement in place
getting the end of the passenger side brake cable threaded through the link piece.

in addition to this you need to unplug the electrical connection above the left drive shaft and release the cable from a locating point on the cross member. It may be a good idea to remove one or both rear exhaust silencers and pipes to provide better access.

I'll post some photos a little later.
Roger S
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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby J44EAG » Tue Mar 12, 2019 2:03 pm

Well done, Roger.

Would it be reasonable to assume that a Main Dealer or Indy would perhaps drop the rear sub-frame out to gain easier access. It sound like it was one of those nightmare jobs.

Any pics perhaps and a write-up for the magazine?

Mike
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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby iRS » Wed Mar 13, 2019 10:07 am

Mike - thanks for that. I think if it was a reasonably new car a main dealer would probably follow the instruction manual and drop the sub frame. I think most Indies would just loosen the diff. Another alternative to consider is to remove the diff. This would give far better access, but would obviously necessitate a partial dismantle of the rear suspension to be able to remove the drive shafts from the diff.

I looked back to the Powerpoint file from the X350 seminar and there are some very good photos in there showing the various components of the EPB system, so fully credit to David Marks for these photos:
Picture1.png
Position of the actuator
Picture3.png
Linkage between main cable and left side caliper cable and electrical connector
Picture2.png
These are with the diff removed.
Roger S
Aberdeenshire
XJS FORUM ASSISTANT COORDINATOR

Early E
1976 XJ-S - original factory manual. Currently in many pieces.
X350 - 2005 Super V8
1962 MGB

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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby iRS » Wed Mar 13, 2019 10:19 am

Here are some photos from my car:

Linkage to left side caliper cable
photo1.png
Linkage between main cable and right side caliper cable (viewable in top-left corner)
photo2.png
Diff bolts loose and actuator mounting screws (note LPG cables/hoses nearby)
photo3.jpg
Note how the top brace bars of the rear subframe get in the way of access to the cable.

I can put something together for a magazine article, but I don't really want to encourage anyone to actually do this job!
Roger S
Aberdeenshire
XJS FORUM ASSISTANT COORDINATOR

Early E
1976 XJ-S - original factory manual. Currently in many pieces.
X350 - 2005 Super V8
1962 MGB

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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby iRS » Wed Mar 13, 2019 1:23 pm

I forgot to say, the park brake works perfectly now and the re-calibration was a simple procedure of a battery disconnect and then simply pulling on the EPB switch while putting your foot on the brake pedal.
Roger S
Aberdeenshire
XJS FORUM ASSISTANT COORDINATOR

Early E
1976 XJ-S - original factory manual. Currently in many pieces.
X350 - 2005 Super V8
1962 MGB

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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby J44EAG » Wed Mar 13, 2019 3:30 pm

An ambitious and interesting job, Roger.

I`m pleased you got a result. The thread certainly gives a good indication of how nasty some of these jobs can be. Not one I could now even contemplate.

ATB

Mike
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Re: Electric Park Brake - EPB - swap out - removal and replacement

Postby ptjs1 » Fri Mar 15, 2019 10:53 am

Well done Roger!

We all too often encounter these really intricate jobs. I well remember changing a foglight on my BMW convertible where it seems the car was originally built by getting the foglight and then building the car around it!

You must be feeling very proud of yourself!

Cheers

Paul
1995 XJS 4.0 Convertible
Jaguar 4.2 Supercharged engine (but not with a Jaguar body..)


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