AK Sportscars AK 427 Manual

AK SPORTSCARS

AK SPORTSCARS
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DEAR FELLOW ENTHUSIAST
CONGRATULATION`S ON YOUR CHOICE OF AN AK 427 COBRA KIT.
THE AK 427 WAS INTRODUCED IN 1990 AND IS THE RESULT ENTHUSIASTS
LIKE YOURSELF WANTING TO SEE A QUALITY PRODUCT THAT WAS
STRONG WITH A FLEXIBILTY OF BUILD ENABLING THE USE OF
DIFFERENT ENGINE GEARBOX COMBINATIONS COMBINED WITH THE
STRENGTH AND RELIABILITY OF JAGUAR RUNNING GEAR.
WE HOPE YOU HAVE MANY HOURS OF ENJOYMENT WITH YOUR BUILD,
THE BUILD MANUAL IS FOR YOUR REFERENCE BUT REMEMBER WE ARE
ONLY A PHONE CALL OR E-MAIL AWAY SHOULD YOU NEED ANY HELP
OR ADVICE. WE CONTINUALLY STRIVE TO IMPROVE AND UPDATE
THE KIT AND MANY IMPROVEMENTS ARE DUE TO OUR HANDS ON
APPROACH AND AK OWNERS FEEDBACK.
THE AK 427 IS DESIGNED WITH FLEXIBILITY IN MIND,YOU BUILD
FROM THE BASIC CHASSIS BODY PACKAGE OR FROM A ROLLING
CHASSIS,WE EVEN DO TURNKEY OPTIONS,THIS FLEXIBILITY
ENABLES YOU TO SPREAD THE COST TO SUIT YOUR CIRCUMSTANCES.
AS WELL AS THE BASIC KIT,WE ALSO SUPPLY SOME OF THE SPECIALIST
PARTS REQUIRED IN THE BUILD WITH OPTIONS FROM STAINLESS STEEL
ENGINE BAY CLADDING TO HEADER TANK`S AND WASHER BOTTLES.
WHATEVER YOUR REQUIRMENTS, AK WILL ENDEAVOR TO MEET YOUR
NEEDS
WE WISH YOU GREAT SUCCESS WITH YOUR PROJECT.
KEN , JON and DAN FREEMAN.

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INTRODUCTION
WE WOULD ADVISE THAT YOU READ THIS BUILD MANUAL IN ITS
ENTIRETY SO AS TO FULLY FAMILIARISE YOURSELF WITH THE
CONTENTS HEREIN.
ALTHOUGH EVERY EFFORT HAS BEEN MADE TO APPROACH THE
BUILD COMPREHENSIVELY, THIS IS NOT A DIFINITIVE WORK AND
IS INTENDED AS A GUIDE WITH WHICH TO ASSIST AND ADVISE YOU
DURING THE BUILD PROCESS.
DUE TO THE VERY NATURE AND CONCEPT OF BUILDING A REPLICA
CAR IN COMPONENT FORM AND THE DIFFERENCES WITH WHICH
EACH CUSTOMER WILL APPROACH THEIR PROJECT, THERE IS GOING
TO BE AREAS NOT ADDRESSED, WITH THIS IN MIND THE CUSTOMER
SHOULD APPROACH THE BUILD AWARE THAT THERE PARTICULAR
CHOICES WILL AFFECT THE FINAL OUTCOME.
WITH THIS IN MIND WE ARE ALWAYS HERE TO HELP AND ADVISE
SHOULD ANY PROBLEMS AND/OR QUERIES ARISE?
WE HAVE SOLVED MANY PROBLEMS FOR PREVIOUS CUSTOMERS
DO NOT HESITATE TO ASK, YOU WONT BE THE FIRST.
GOOD LUCK.
KEN, JON and DAN

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CONTENTS
CHAPTER ONE…………. Your AK 427
Specification
Engine and Gearbox options
AK 427 Kit contents
Optional Parts Manufactured by AK
Donor list
Parts suppliers list and approximate costs
CHAPTER TWO…………. Preparation
Safety
Tools
Workarea
CHAPTER THREE……… Chassis/Body
Chassis support and preparation
Body storage
CHAPTER FOUR………… Running gear/Suspension
General information
Selection of suspension/Running gear
Front suspension stripping/preparation
Rear suspension stripping/preparation
Ready to rebuild
CHAPTER FIVE………….. Chassis build
Front suspension fitting
Rear suspension and differential fitting
Brake lines/pipes
Fuel tank
Fuel pump and fuel lines/pipes
CHAPTER SIX……………. Engine/ Gearbox/ Exhaust
General information
Fitting
CHAPTER SEVEN……….. Cooling System
Radiator/fitting
Header tank
Plumbing/hoses
Electric fans/thermostatic control

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CHAPTER EIGHT……….. Body/Fitting
Preparation/fitting body
Roll bar & seatbelt brackets
Windscreen
Door locks
Screen washers
Boot Hinges/locks/bonnet stays
Lights/Head /Indicators/Brake/Number plate
Petrol filler/Pipework
Nudgebars/Overriders
Seatbelts
CHAPTER NINE…………. Cockpit/components Mechanical
Pedal box assembly
Steering column
Handbrake
Heating system
Wiper motor/wipers
Instrument panel/instruments/Switchgear
CHAPTER TEN…………… Electrical
Wiring loom/Fitting
Cockpit
Engine bay
Dashboard
Front lights
Rear lights
CHAPTER ELEVEN……… Cockpit/Components Upholstery
Carpets
Door panels
Seats
CHAPTER TWELVE…….. Finishing
Wheels/Tyres
Hood.

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YOUR AK 427
SPECIFICATION
CHASSIS………………… Ladder frame construction of 75 x 50 x 3.2 section steel
for the main rails and 25 x 25 for the backbone section,
floors are paneled in 12 gauge steel for extra stiffness.
The chassis is jig assembled for accuracy of and comp-
nent fit ensuring correct suspension geometry
SUSPENSION……………. Front
XJ6/POST 1974.Front Upper and lower wishbones,swivel
hub assembly,stub axles,AK supplied mounting plate for
coil over shocks,AK supplied coil over shock absorbers
Rear
XJ6/POST 1974.Driveshafts and lower wishbones shortened
supplied by AK on an exchange basis,rear axle tie bars
supplied by AK,rear diff mounting bracket supplied by AK
rear hub assemblies.
STEERING……………….. Rack and pinion modified and supplied by AK and Rover
SD1 steering column
BRAKING SYSTEM…….. Pedal box, servo, master cylinder (Dual circuit) sourced from
Morris Marina,Pedals modified by AK,or AK manufactured
pedal box using rover 214/216 master cylinder incorporated
with front and Rear calipers and Discs (vented front) from
Jaguar XJ6.
FINAL DRIVE……………. Differential from Jaguar XJ6/12/s
RATIOS 3:54:1 for Rover 3500
3:31:1 Larger capacity(350 ci)
3:07:1 With 4 speed box
2:88:1 Automatic box
Utilising Jaguar Or Rover Propshaft shortened to fit.
BODY………………………. GRP body gel coated to customer choice constructed in mold
With only three main components (multi layered chopped
Glass mat layed for strength in key areas,Cockpit and Boot
Jig bonded to shell for accuracy and rigid monocoque,double
Skinned Bonnet,Boot and Doors,complete with interior side
Panels and Dashboard.
WHEELS/TYRES.………… Halibrand replicas with spinners 16inch or 17inch,check with
AK for correct OFFSET.
ENGINE & GEARBOX APPLICATIONS
GENERAL INFO………….. The AK 427 is designed to accept various Engine and Gear
box combination`s, listed below are some that have been
applied previously to the AK chassis,and have proved to be
reliable,easily fitted and giving excellent performance in
keeping with the concept of the original.

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YOUR AK 427
ENGINES………………….. ROVER V8, 3500cc/3900cc/4200cc/4500cc/5000cc/6300cc
Although expensive to tune in its standard forms ie 3.5ltr
3.9ltr and 4.2ltr this is a very capable engine of light weight
compared to alternatives and extremely reliable with an
output of 165bhp to240bhp,the tuned versions of all the
above whilst an expensive process can yield power outputs of
over 350bhp the power to weight ratio of this engine and its
CHEVROLET (small block) 265ci/283ci/302ci/327ci/350ci
4 bolt mains, cast iron or aluminium cylinder heads,solid or
hydraulic or solid lifters, power outputs of 170 bhp to 380bhp
achievable,these engines are easily obtainable and comparat
ively inexpensive to tune compared to the rover, although it
is heavier due to being a cast iron block.
FORD V8, 221ci/260ci/289ci/302ci/351ci the 289 being the
original choice of these engines as fitted by Mr Shelby himself
like all the above Chevrolet engines the Ford power units
lend themselves to tuning with high outputs attainable
BIG BLOCK CHEVROLET AND FORD,whilst these engines
Appeal is obvious,a tight fit and cooling can cause there own
headaches.
GEARBOXES……………… ROVER 5 speed for Rover engines
CHEVEROLET,T5 or T10,Trimac or Getrag
FORD, T10 or 4 speed top loader or or any of the above as
fitted to chevy with suitable adaptors.

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YOUR AK 427
LEADING DIMENSIONS
& DESIGN WEIGHTS
AK 427 DESIGN WEIGHTS.
AXLE 1 638 kg
AXLE 2 780 kg
GROSS 1400 kg

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YOUR AK 427
AK 427 KIT CONTENTS
CHASSIS…………………………Ladder type with partial backbone and full steel lowered
Floors
BODY…………………………….Finished in white gel coat,(colours optional)
• scuttle hoop bonded into full inner tub
• body temporarily bolted to chassis
• doors and bonnet pre-hung
• top and bottom radiator frame
• steering rack
• track rod ends
• steering arms
• steering rack to column extention
• front shock absorber mounting plates
• engine and gearbox mounting plates
• wiper motor bracket (attached to scuttle hoop)
• steering column bracket (attached to scuttle hoop)
• handbrake mounting bracket
• handbrake cable
• rear axle tie bars
• shortened rear wishbones (exchange)
• shortened driveshafts (exchange)
• roll bar mountings
• front and rear nudge bar mounting brackets
• dashboard (blank)
• interior trim panels
• glove box moulding
• modified pedal box (exchange)
• all body holes marked or pre-cut
• holes drilled and tapped for door locks
• rear differential mounting bracket

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YOUR AK 427
OPTIONAL PARTS SUPPLIED BY AK
(all prices plus VAT)
COIL OVER SHOCKS (6 of)
PETROLTANK STAINLESS STEEL (14 gall)
HEADER TANK (stainless steel polished)
WASHER BOTTLE (stainless steel polished)
REAR WHEEL ARCH STONEGUARDS
(stainless steel)
SIDE VENT`S (stainless steel)
BONNET AND BOOT GAS RAMS plus fitting kit
STAINLESS STEEL ENGINE BAY CLADDING
(cut and folded)
STAINLESS STEEL ENGINE BAY CLADDING
(fitted prior to delivery)
SEAT SHELL`S
SEATS --- LEATHER
SEATS --- VINYL
UNDERFLOOR EXHAUST SYSTEM and MANIFOLDS
STAINLESS STEEL SIDEPIPES and MANIFOLDS
AK MANUFACTURED PEDAL BOX –
uses ROVER 214/216 servo/master cylinder

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YOUR AK 427
DONOR PARTS LIST
JAGUAR POST 1974 (VENTILATED FRONT DISCS)
FRONT AXLE GET SCRAP YARD TO CUT OFF COMPLETE SUBFRAME
REAR AXLE COMPLETE ON SUBFRAME
RATIOS 3.54:1 For 3500 Rover engine
3.31:1 Larger capacity engines
3.07:1 For 4 speed gearbox
2.88:1 With autobox
PROP SHAFT Jaguar (or Rover prop)
JAGUAR XJS
HAND BRAKE ASSEMBLY (or new item from Jaguar approx £60:00)
ROVER SDI
RADIATOR (standard for Rover 3500, 3 row core No BTP 1019 for larger capacity engines)
STEERING COLUMN (complete with attachment bolts and lower column support bracket)
ENGINE AND GEARBOX
REV COUNTER (use chip to convert triumph or Jag to 8 cyl)
WASHER BOTTLE & PUMP (small bottle)
MARINA or ITAL
DUAL CIRCUIT PEDAL BOX COMPLETE or AK manufactured pedal box assembly
WIPER MOTOR,GEARBOXES & CONNECTING TUBES
POLO MK1
HEATER
TRIUMPH
ACCELERATOR PEDAL
DASH WITH ALL CLOCKS (2.5 or dolomite or Jaguar)
ALLEGRO or METRO
2 ELECTRIC RADIATOR FANS

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CHAPTER TWO
PREPARATION
SAFETY………………….. There are many dangers in the workshop,we cannot stress
enough the need for safety, you need to be aware of the inherent hazards surrounding you whilst
building and stripping mechanical components and in using electrically operated power tools.
The completion of this project is more easily embarked upon if you use common sense when
applying safety procedures and cleanliness in the work area as part of your routine before
and after and during the build process each day.
GRP. Glass reinforced plastic (fibreglass) is a hazardous material and adequate precautions
should be taken in its use and preparation,
HAZARDS.
I. Dust in the air from filing, drilling, cutting and sanding.
II. Sharp edges and splinters.
III. Fumes from resin.
WEAR PROTECTIVE CLOTHING ,FACEMASK and KEEP WORK AREA WELL
VENTILATED.
REMEMBER…
DO DON`T
Use eye protection when using power Attempt to lift heavy components without aid
tools,and when welding or under the always get help.
vehicle.
Take short cuts to finish a job.
Keep loose clothing and long hair out
of the way of tools and moving parts. Use damaged or ill fitting tools which may slip
and cause injury.
Remove rings wristwatches and any-
Thing that may get caught. Leave tools or parts or oil and fuel spills lying
Around always clean up.
Ensure that jacking equipment/axle
stands have sufficient load capacity. Allow children or pets near the vehicle whilst
it is supported on jacks/stands, or whilst using
If working alone get someone to check power tools/welding equipment
on you periodically
Smoke near inflammable chemicals
Make sure you have sufficient time to
complete tasks

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DUST. Can cause irritation to the eyes and skin, block nasal passages and cause respiratory
Problems clean all work area after working with GRP. ie. After sanding, cutting and
Drilling.
EYES. Wear protective eye glasses whilst carrying out operations with electrical tools, such
As grinding, drilling, sanding.
FIRE. The workshop will be full of combustible materials and the fire hazard cannot be
Overstated, it is in your own interest to invest in a fire extinguisher and take simple
precautions to prevent the risk of fire.
I. NO SMOKING in the workshop.
II. ALL PETRO CHEMICALS stored in a steel locker/drawer
III. ELECTRICAL TOOLS unplugged and wire coiled neatly (trip hazard).
IV. RAGS AND PAINTBRUSHES used with chemicals (petrol/thinners) tidied away
so as not to be ignited by sparks from welding/grinding
SUPPORTING THE CAR. It cannot be stressed enough that the chassis/car is supported on
sturdy axle stands or ramps NEVER work on the vehicle only supported on a jack or unsuitable
items such as wooden blocks or bricks.
TOOLS………….
If you consider the outlay already on purchasing your AK, it is obviously worthwhile to invest
in adequate tools for the job in hand.
Depending on which jaguar was donor vehicle early cars were imperial, later cars metric, you
will require :
SOCKET SET. 3/8in to 1 ¼ in AF . or 10mm to 32mm. ½ inch drive with long and short
extensions and universal/wobbly joint attachment. 3/8 inch and ¼ inch drive sets would also
be useful.
COMBINATION SPANNERS 3/8 in to ¾ in AF. or 10mm to 19mm.s
SCREWDRIVERS various sizes, flat bladed and crosshead/posidrive.
MOLEGRIPS, ADJUSTABLE SPANNERS, ALLEN KEYS (hex wrenches) FILES, HAMMER
RUBBER MALLET and HAND DRILL
PLIERS. Various long nose, square jaw and circlip pliers(for internal/external circlips)
wire strippers/crimpers, side cutters.
STANLEY KNIFE, SPIRIT LEVEL, VARIOUS SAWS (for metal and wood).
ELECTRICAL TOOLS…. Grinder , sander, Drill and various bits.

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MISCELLANEOUS…….. tape measure/ruler , spirit level , marker pens, masking tape.
SPECIAL TOOLS…… pullers, spring compressors ( Hire shops are good source for these)
WORKSHOP/GARAGE.
Working on or around the vehicle requires space, a double garage is preferable but not
available to all, so consider your work area and storage facilities, room to lie on the floor and
stripping down of donor parts and storage of same.
Keep the floor areas clean and tidy, so consider shelving for storage, various containers for nuts/
bolts/screws and all the other bits and pieces you will acquire during the build process.
Also consider storage of tools and availability, a workbench is a bonus but workmate will suffice
you will also need the use of a vice and electrical sockets.
Invest in a FIRE EXTINGUISHER a fire blanket and a bucket of sand , you may need them !
IT IS ALSO ADVISABLE TO SECURE YOUR WORKSHOP.YOUR PROJECT IS VERY
VALUABLE AS ARE THE TOOLS TO BUILD IT.
With all this in place you are now ready to embark on your project.
THINK CLEAN : THINK TIDY
THINK SAFE

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CHAPTER THREE
CHASSIS/BODY
CHASSIS SUPPORT/PREPARATION……
The chassis /bodyshell is received with the body temporarily fitted to the body, it is advisable
at this stage before removal of the bodyshell to mark the exposed chassis rails in the engine bay
with a piece of chalk, or to make a template of the engine bay area as this will assist in the
positioning/fitting of brake lines and fuel lines.
You will have also receive other items necessary for your build, namely nudge bar brackets,
shortened wishbones, roll bar brackets, various nuts and bolts for body to chassis fitment.
A full list can be seen in the chapter <YOUR AK 427>.
SUPPORTING CHASSIS.
The chassis needs to be on level ground, supported on axle stands and at a height to enable
getting underneath, to enable the correct set-up of the suspension components the chassis will
need to be level front to rear and side to side.
PAINTING CHASSIS.
The AK chassis is fully painted by AK unless specified by the customer that they wish to prepare
and paint the chassis themselves, you can also paint it again yourself at this stage if you wish.
BODYSHELL STORAGE…..
Removing the body from the chassis will require the help of a up to four able bodied people as
the bodyshell is heavy, store the body away unless you are dressing out the engine bay and/or
you are using a coloured gel coat and are preparing it yourself.
also some items that will need to be fitted to bodyshell before refitting to chassis, such as pedal
box and heater assembly.
IMPORTANT NOTE RE: BODY STORAGE. ONCE YOU HAVE REMOVED THE
BODY FROM THE CHASSIS IT NEEDS TO BE STORED ON A LEVEL SURFACE
WITH THE BOOT AREA SUPPORTED, TO ASSIST IN THIS YOU WILL FIND
WATCHING CLOSELY THE DOOR GAPS AND MAINTAINING THE GAP THAT
WAS APPARENT WHEN MOUNTED ON THE CHASSIS.

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CHAPTER FOUR
RUNNING GEAR/SUSPENSION
GENERAL INFORMATION
DONOR VEHICLE.
The chassis of your AK has been designed to work with the suspension components and running
gear from the XJ6 and XJ12 Jaguar, post 1974 series 2 or 3 models.
SELECTION.
The purchase of a complete Jaguar donor vehicle is necessary as you will require the log book
from the vehicle, although it is possible to obtain parts required from vehicle dismantlers and
purchase a scrap jaguar for its logbook.
When selecting your donor vehicle, it is in your interest to select as low a mileage jaguar or one
that you have inspected the suspension components to ascertain the amount of refurbishment
required, it is also important to select a vehicle with the ventilated disc and four piston calliper
set-up as this is superior to the earlier solid disc and three piston caliper arrangement on earlier
cars.
You also need to take the final drive ratio into consideration and check it is suitable for your
engine/gearbox combination, refer to information in chapter <YOUR AK 427>.
FINAL DRIVE RATIO determines the acceleration and maximum speed of the vehicle, a high
figure (ie, 3:54:1) gives faster acceleration but lower maximum speed, a low figure (ie 2:88:1)
gives lower acceleration but higher maximum speed.
: IMPORTANT NOTE :
YOU MUST USE THE FRONT VENTILATED DISC
AND FOUR POT BRAKE CALIPER SETUP, THIS IS
FOR SAFETY AND SUPERIOR BRAKE EFFICIENCY
THE INFORMATION ON STRIP DOWN & OVERHAUL OF
SUSPENSION COMPONENTS IS INTENDED AS GUIDANCE
ONLY, YOU MUST USE THE RELEVANT WORKSHOP
MANUAL AS THE PRIME REFERENCE

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The suspension components are mounted in subframe assemblies, you need to remove these
from the donor vehicle first, then remove the suspension components and brake components
from subframes, rusted nuts and bolts are best soaked overnight if possible with penetrating
oil or similar to aid the strip down procedure, wire brushing around nuts bolts and threads
will aid removal and make the task a lot easier.
FRONT SUSPENSION STRIPPING/PREPARATION.
Work on one side at a time, begin with the removal of the brake calipers and discs, you will need
coil spring compressor for next step, removal of coil spring,
After removal of the six retaining bolts holding spring platform to lower wishbone remove the
spring, undo nuts securing upper and lower ball joints separate from stub axle carrier and
remove carrier. Remove both wishbones; the upper wishbone is in two halves; also note carefully
the position and number of camber shims for replacement during rebuild.
Repeat procedure for the other side.
Clean all components with paraffin and wire brush ready for painting, do not paint bearing
surfaces, use an enamel or hammerite or have parts powder coated,
make a list of parts that will need replacement.
You will not require the following parts: dustshield / steering arm / shock absorbers / anti roll
bar / subframe. refer to diagram front suspension, as some of the above parts are AK
replacement items.
When reconditioning/rebuilding the front suspension, it is advisable to renew as many of the
items listed below as possible for your own safety, they are in all likelihood worn and need
replacement.
ie: upper and lower ball joints / bearings and races / bushes /new ventilated discs / refurbished
exchange calipers.
REAR SUSPENSION STRIPPING/PREPARATION.
Remove the suspension components from the subframe first, this will involve the removal of the
tie plate which is under the final drive housing and ties the subframe together, the bolts securing
this plate are invariably rusty, the six bolts into the subframe halves can be chiselled or ground
off, the bolts which fix the plate to the final drive housing need to be unscrewed as once the final
drive is placed into the AK chassis a metal plate is fixed to the underside of the final drive
housing to protect fuel line which runs under the housing.
:WARNING:
THE FRONT SPRINGS ARE UNDER A GREAT DEAL OF TENSION
UNTIL THE PRESSURE IS RELIEVED HANDLE WITH CARE AS
THIS EXERCISE CAN BE DANGEROUS

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NOTE: remove the top centre bushes from the rear shock absorbers, you will
require them for fitment of the front shock absorbers when rebuilding.
Keep the shims from drive shafts to disc, as these are required for camber set-up, and the shims
from the inner pivot mounting.
The driveshaft universal joints will need to be removed and the driveshaft flange and splined
yoke kept, the driveshafts are returned to AK for shortened items along with the wishbones.
The bolt and bush holding the original pressed steel radius arm in position are also required for
fitment of radius arms supplied by AK, you will notice the bolt has half of the hexagonal head
removed; this is so it will pass the shock absorber flange, retain this bolt and bush.
make a list of parts that will need replacement.
You will not require the following parts: radius arms / shock absorbers / coil springs / subframe.
When reconditioning/rebuilding the rear suspension, it is advisable to renew as many of the
items listed below as possible for your own safety, they are in all likelihood worn and need
replacement.
ie: driveshaft Ujs / Lower wishbone needle rollers / rear discs / hub carrier bearings /
refurbished exchange calipers.
Drain gear oil from final drive/differential .
The final drive /differential examine for any pinion backlash, renew the two driveshaft output
seals and the front input seal (there is no need to dismantle the differential to do this).
Clean all components with paraffin and wire brush ready for painting, do not paint bearing
surfaces, use an enamel or hammerite or have parts powder coated.
READY TO REBUILD
With all donor parts refurbished and necessary components replaced with new items, along with
the exchange driveshafts and wishbones from AK, you should also have purchased the six coil
over shocks required and can now rebuild the front and rear suspension assemblies and fit them
to AK chassis.
: PLEASE NOTE :
AK WILL SUPPLY YOU WITH SHORTENED REAR WISHBONES
AND DRIVESHAFTS ON AN EXCHANGE BASIS.

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CHAPTER FIVE
CHASSIS BUILD
FRONT SUSPENSION / REBUILD AND FITTING.
PARTS REQUIRED ……. refer to diagram for AK front suspension.
Upper wishbone / wishbone pivot shaft / Camber shims.
Upper and lower wishbone bushes.
Lower wishbone / Lower wishbone pivot shaft.
Upper ball joint / distance piece / castor control shims.
Lower ball joint.
Stub axle carrier / stub axle.
Wheel hubs.
Wheel bearings / bearing races / seals.
Ventilated discs
Brake callipers (4 piston type)
Track rod ends (for steering rack, AK supplied part).
Steering arms ( AK supplied part).
Mounting plate for shocks (AK supplied part).
Coil-over shock absorbers (purchased from AK).
All nuts / bushes / washers.
Locking wire.
Shock absorber bushes from rear suspension.
REBUILD / FITTING.
Fit the two upper wishbone arms to the upper pivot shaft using the required bushes and
washers.
Fit top/upper ball joint between the wishbone arms using the castor control shims, start with
three between front wishbone arm and ball joint casting and distance piece (this is a temporary
set-up, castor will/may be adjusted later with car at ride height, they must also be fitted to avoid
distortion of bushes at pivot shaft). (figs 5.1 / 5.2)
: IMPORTANT :
THE INFORMATION REGARDING REBUILDING AND REFURBISHMENT OF
SUSPENSION COMPONENTS IS FOR GUIDANCE ONLY, YOU MUST REFER
TO THE RELEVANT JAGUAR WORKSHOP MANUAL AS THE MAIN
REFERENCE FOR THE REBUILDING PROCESS AND TOR
Q
UE SETTINGS