How to Repair the Headrest on a Jaguar XK8 / XKR

Here's a new, improved video of the headrest repair! Many XK8s and XKRs suffer from a problem where the headrests get stuck and don't move. The cause is a drive cable that has a jacket that is slightly too long. The solution is to open up the seat, cut the jacket on the drive cable, shorten it slightly, and repair it with shrink wrap. This video shows how to do it.
All it takes is a T-25 Torx wrench, a thin screwdriver, a razor blade or sharp knife, some heavy duty, thick-walled, adhesive shrink wrap, and a heat gun. If you don't have a heat gun, a propane torch will work, just be careful not to leave the flame in one spot for too long. Total time for the repair is probably less than an hour per seat. Having done it several times now, I can probably do both seats in under an hour. But if you're doing it for the first time, you should probably set aside at least an hour per seat.

[@guzzisvt4734]

I just got done doing both my seats in my 2001 XKR Coupe. I did what Sam referred to in the video because he was having trouble with the splice. I cut of just the metal end and cleaned out the old sheath then drove the smooth end of a 5/16 drill bit though it to allow the cable sheath to feed back into it (16mm). It was still tight as I had to hold the sheath with vise grips and use a small hammer to drive it home. I took the drivers seat out but did the passengers seat while still in the car. Thanks Sam!

[@sam1174]

No problem, Guzzi. I cut the cable in the middle, originally, but it's hard to get the two pieces to join and stay joined. You definitely did it the right way.

[@Cerberus3979]

Thank you for the Video! It has given me the confidence to get this repair done on my 2001 XKR. FYI, the sound in this video cuts out every so often for longer and longer. YOU CAN still get the point but seems to cut out during every particular important bit of info you want to pass along :D

[@fenderstratguy]

Great video! One question: is part of the audio going in and out? I'm wondering if you could upload it again? I think some of the audio that is missing might be important.

[@asaleemeadows]

Picked up an 04 xkr last November. Just did the drivers side today. 🎉 Looks like previous owner or shop attempted repair because some of those clips were broke behind the leather. Oh well. It all went back in ok. Will do the passenger side tomorrow.

[@nilslarsson4266]

Hi, thanks for the video, went in and out between video and garage and now one side is fixed, plan to do the other side tomorrow. Much appreciated Best regards Nils

[@rubblejohnstone4460]

Just to say about 5 years ago I found your channel, watched every video and bought a down at heel xk8 convertible. Have spent time restoring it and even my wife now loves it. Just to say I still love your videos and I have some tips on repairing the front sub frame if you would like them.

[@sam1174]

Thanks Rubble. I sold my XK8 about 7 years ago and I've been regretting it ever since. I keep looking for another one, but the decent ones are too expensive and the reasonable ones are worn out and falling apart. If you keep yours in good shape I'm sure it will retain its value.

[@rubblejohnstone4460]

Thanks Sam, good luck your an inspiration.

[@kurtbaker3641]

Great video and it looks like my question was answered as I was gonna ask if you would have done it differently, and it looks like cutting the end off is a lot better and more solid of a fix than the middle, great video remember to always include after thought, aka what you would have done differently, it seems you did mention the part about cutting it next to the metal but then it cut out, either way great video for getting to the motor

[@sam1174]

+Kurt Baker Yep, in hindsight I should have cut one end off, removed the jacket from inside the end, and then slid the end back onto the jacket. Cutting in the middle will work, you just need some really, really thick heat shrink tubing. The kind that has glue on the inside.

[@Rons45Eagle]

Hi Sam, I have to do this headrest job on my 2002 XK8, The video was great. BUT the most important thing , In car repair , Did you disconnect the battery or just disconnect the wiring under the seat. Safety First. Please let me know. Thanks Ron

[@sam1174]

To be safe you should disconnect the battery, although I don't think it's really necessary. Better safe than sorry, though.

[@moyadapne]

Thanks for this. I'm gonna do mine now. I presume you disconnected the battery in case the side air bag went off.

[@omgitsBenjamin]

I'm not really getting HOW it stops working. Like mechanically what happens? Mine don't go up/down but the motor runs. What exactly is not connected or working? I was told it has a belt driven mechanism. Can you explain more what in my case I would need to fix?

[@sam1174]

omgitsBenjamin Imagine a long, flexible rod inside a sleeve. The rod has a square end which fits into a square hole. When you turn the rod the headrest goes up or down. But if it is too short, sometimes it doesn't quite reach the square hole it's supposed to plug into and it slips out. By shortening the sleeve the square end of the rod goes deeper into the square hole. It doesn't slip out when it's turning. When you take it apart it will make perfect sense.

[@omgitsBenjamin]

Okay, thank you so much.

[@gcjabo]

Great video...poor audio

[@richardsmith9509]

You should be using a considerably smaller (diameter) shrink tubing This is way too big

[@jaglover]

What's with the audio cutting out

[@DocHuard]

Not bad, some helpful info, but the audio cutting out makes it really hard to watch for anyone without a great amount of patience. :-)