4.1.11 Coil over damper mounting with spacer
The 5/8” ID x 3/8” spacers should be fitted inside the upper and lower bushes on the forward most units.
Ensure that a 1/2”ID x 11/8” OD “mudguard” washer is fitted on the outside of each shock eye to ensure that
they remain captive in the event of rubber bush failure. Fit the two washers with the 3mm holes drilled near
the edge to the forward upper mounts, these holes are to retain the handbrake return springs.
Tighten the 8 nyloc nuts to 35lb-ft.
4.1.12 Rear tie bars
Fit the rear end of each tie bar to the bracket attached to each rear hub using the 1/2”UNF x 21/2” bolts &
nyloc nuts. Fit loosely at this stage. By screwing the Rose joints in or out of the tie bar, set them so that the
two 1/2”UNF x 4” bolts fit easily through the attachment point on the chassis to the eye of the joint, and the
lengths of the two tie bars are equal. This should be done with the rear suspension set such that the drive
shafts are horizontal. This sets the rear wheel alignment approximately true. The bolt should be fitted from
the inside so that the nut faces outward. This allows the Rose joint to be detached to adjust rear wheel
alignment. (With the bolt fitted the other way the body would prevent it being withdrawn). Alignment should
be checked and reset as necessary at a garage with optical alignment equipment at a convenient time before
road running the car. Now tighten the 4 tie bar fixings to a torque of 40 lb-ft.
4.1.13 Handbrake return springs
Install the handbrake caliper return springs between the calipers and the drilled washers (photo 3), these may
need holding in a bench vice and pre expanding a little before they will fit nicely.
4.2 Front suspension.
You will need the following parts for this operation:
a) Reconditioned from the donor car:
• Lower wishbones (2) Upper wishbones (2) - the wishbones of some early XJ6’s were different from
the majority, see figure 4 and the foregoing text
• Stub axle and stub axle carrier (2)
• Upper part of disc protector (to which the brake hose attaches). The lower part can be discarded.
• Steering arms (2)
• Brake callipers (2)
• Front hub & brake disc assembly plus washer, castellated nut & end cap (2 of each)
• Castor adjusting shims (2 sets)
• 3/8”UNF upper ball joint bolts (21/2” & 33/4” in length, 2 of each)
• Upper wishbone pivot shaft (2)
• Lower wishbone pivot shaft (2)
• Dedicated bolts for securing brake callipers and steering arm to hub axle carrier (6)
Note : These bolts are specials, some having metric threads. Do not try to replace them with
standard bolts.
• A 6” length 12mm studding, washers, nuts and a tubular spacer see Fig 1
b) Plus the following new items:
• Special spacers (13/16” ID x 3/8”) for mounting lower wishbones. (2)
• Front brake pads (4)
• Upper ball joint (2)
• Lower ball joint (2)
• Lower wishbone bushes (4)
• Upper wishbone bushes (4) and chrome washers (8)
• Mounting plate for shock absorber to lower wishbone (2)
• Coil over shock absorber units (springs already fitted) - (2)
• Brake calliper setting shims as required
• Dummy André Hartford shock absorbers (2)
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