ESP RENAULT KANGOO 1997 KC / 1.G Chassis Workshop Manual

REAR AXLE
Brake cylinder
REFITTING
Remove all dust from the drums and the linings
using brake cleaner.
Refitting is the reverse of removal.
Bleed the braking circuit (see section 38).
Adjust the linings by repeatedly pressing the
brake pedal.
Check the cut-out pressure (see section 37
"Controls").
TIGHTENING TORQUES (in daN.m)
Wheel bolts 9
Hub nut 17.5
Bleed screw 0.5 to 0.8
Pipe bolt 1.7
REMOVAL
Remove:
- the drum (see corresponding section),
- the upper return spring (see paragraph
"Brake linings").
Separate the shoes.
Slacken:
- the rigid pipe union on the wheel cylinder
using a pipe wrench,
- the two cylinder mounting bolts on the
backing plate and remove it.
Check the condition of the shoes. If they have
traces of oil on them, renew them.
33
33-4

Emb. 880 Inertia extraction tool
Rou. 943 Hub cover plug extractor
REAR AXLE
Brake linings (drum)
SPECIAL TOOLING REQUIRED
Wheel bolts 9
Hub nut 17.5
33
TIGHTENING TORQUES (in daN.m)
Composition of RAI brake (Rattrapage Auto-
matique Incrémental - automatic wear take up
system).
ALeading shoe
BTrailing shoe
CFixed point
PBase of brake shoe
FRAI wear take up system
1Upper return spring
2Lower return spring (for base)
3Side retainer
4Handbrake lever return spring
REMOVAL
Brake shoes must be replaced on the complete
axle - never fit shoes of differing makes or
grades.
Remove:
- the brake drum (see corresponding paragraph),
- the lower spring (2) using brake shoe pliers.
Using adjustable pliers, remove the shoe side
retaining springs.
In turn, pass each brake shoe base over the fixed
point. Squeeze the bases of the shoes together to
separate the ends at the wheel cylinder end.
Separate the assembly (RAI and shoes) from the
brake backing plate then remove it, after
unclipping the handbrake cable.
98992-2R
33-5

REAR AXLE
Bearing
SPECIAL TOOLING REQUIRED
Emb. 880 Inertia extraction tool
Rou. 943 Hub plug extractor
TIGHTENING TORQUES (in daN.m)
CHECKING
Check the end float using a dial gauge mounted
on the drum : 0 to 0.03 mm maximum.
REMOVAL
Remove:
- the hub plug using tools Rou. 943 + Emb. 880,
- the brake drum (see corresponding
paragraph).
From the drum, remove:
- the bearing retaining clip,
- the bearing using a tube.
Hub nut 17.5
Wheel bolts 9
33
REFITTING
Using a tube and a press, fit the bearing until it
touches the shoulder.
Fit:
-a new clip,
- the drum on the pre-lubricated stub axle,
-a new lock nut and tighten to the correct
torque,
- the hub plug.
Adjust:
- the brake shoes by repeatedly pressing the
brake pedal,
- the handbrake (see section 37 "Controls").
33-7

REAR AXLE
Half suspension arms, tubular rear axle
REFITTING
Ensure the bearing races or the needle bearings
are in perfect condition, otherwise replace them
(see section "Bushes, tubular rear axle").
The needle bearings are greased for life and do
not require further lubrication.
NOTE : new suspension arms are supplied by the
Parts Department fitted with bearing races or
needle bearings (depending on side).
Fit the two half suspension arms together until
dimension (B) is obtained.
NOTE : dimension (B) corresponds to the distance
between the same two mounting points for the
anti-roll bar on the suspension arms. It is therefore
possible to obtain this dimension by positioning
the anti-roll bar in its location and checking the
mounting bolts can be correctly positioned.
Ensure the fitting direction is observed.
Refitting is then the reverse of removal.
NOTE : if the half suspension arm is renewed,
bond the brake backing plate mounting bolts
with
Loctite FRENBLOC.
Bleed the brake circuit.
Adjust the handbrake control (see section 37).
33
TIGHTENING TORQUES (in daN.m)
Bearing mounting nut 11
Anti-roll bar mounting bolt 5.5
Wheel bolt 9
Shock absorber base bolt 8.5
REMOVAL
Put the vehicle on a two post lift, remove:
- the anti-roll bar,
- the lower shock absorber mounting,
- the secondary handbrake cable, disconnecting
at the central adjuster under the vehicle,
- the brake pipe,
- the two bearing mounting nuts (A).
Slacken the two nuts (A) on the other bearing so
the half suspension arm can be released from its
mountings.
Remove the half suspension arm, separating one
from the other.
13132R1
86320R
33-10

REAR AXLE
Bushes, tubular rear axle
Press on the assembly (D) and (C) until the sleeve
(C) reaches the edge (3) of the tube.
Fit :
- the small bearing race in sleeve (C),
- sleeve (C) on the tube, using sleeve (D) as a
guide.
On the press, press on until the sleeve (C) reaches
the edge (3) of the tube.
Remove sleeves (C) and (D).
IMPORTANT
When pressing on the parts, if the weight has
been taken on the axle mounting bearings, it
must be ensured that the suspension arms are
correctly located in their mountings (risk that
they may have been moved).
Recentre them if necessary.
Assemble the two half axle sections.
NOTE : the needle bearings are greased for life
and do not require further lubrication.
Reconnect and refit the rear axle assembly to the
vehicle (see corresponding section).
33
90867-2R90867-4R
90867-3R
33-14

REAR AXLE
Suspension arm bearings
This operation is carried out after removing the
rear axle assembly and the suspension bars.
REMOVAL
Weld a spacer (example : nut) in the central tube
of the bush.
Remove the bush - bearing assembly on the press.
REFITTING
The bearing is fitted in the arm, ensuring the cor-
rect alignment is observed and the clearance bet-
ween the bearing and the arm is correct.
Alignment
Observe dimension "X" between the bearing
pressure face and the stub axle shaft
X = 124 ± 3.5 mm
Clearance
In this position, press on the bearing until the
dimension between the bearing centres is :
Y = 1164 ± 1 mm
Fit the rear axle assembly to the vehicle and refit
the suspension bars (see corresponding section).
FOUR BAR REAR
AXLE
33
90241GDI3312
DI3313
33-22

85920R2
WHEELS AND TYRES
Specifications
Examples of identification marking
165/70SR1383
125463
165/70 R 13 83 S
TYRES
35
1165
702
3S
R
513
4
Tyre width in mm ( l ) section
Ratio h/lheight
width
Speed index 180 km/h maximum
Radial structure
Inner diameter expressed in inches. Corresponds to the diameter of the rim.
836Load index
Some speed symbols :Maximum speed km/h
R 170
S 180
T 190
U 200
H 210
V 240
ZR over 240
Types of structure :
Diagonal No marking
Radial R
Bias belted B
35-2

MECHANICAL ELEMENT CONTROLS
Braking compensator
37
NOTE
the braking compensators differ depending on the type of rear axle:
-standard load rear axle: red reference mark,
-increased load rear axle: green reference mark,
REMOVAL
Put the vehicle on a two post lift.
Disconnect the brake pipes.
Disconnect rod ( 2 ) from the compensator by
slackening bolt ( 1 ).
Remove the compensator (two bolts).
12865-1R
TIGHTENING TORQUES (in daN.m)
Hydraulic unions 1.7
Compensator mounting bolt 1.8
Rod adjustment bolt 1
NOTE : do not alter the position of nut (3).
REFITTING
Refitting is the reverse of removal.
Bleed and check the circuit (see section "Checking
- Adjusting").
SPECIAL TOOLING REQUIRED
Fre. 244 -03
or
Fre. 1085-01
CHECKING
Connect two pressure gauges Fre. 244-03 or
Fre. 1085-01 :
- one at the front right hand side,
- one at the rear left hand side.
Bleed the pressure gauges via screw (P).
98828R
Progressively press the brake pedal until the
pressure at the front wheels is the setting
pressure (see table of values). Read the
corresponding pressure at the rear wheels;
correct it if necessary.Pressure gauge for checking
compensator rating
37-12

MECHANICAL ELEMENT CONTROLS
Braking compensator
37
6• Calculating the tyre deflection:
- subtract the two measurements made to obtain
the tyre deflection.
7• Carry out stages 4, 5 and 6 for the other rear
wheel.
8• Calculate the average deflection for both
tyres:
- add the two values for the two deflections
noted for the two rear wheels and divide the
result by two to give the average deflection.
9• Reading the graphs:
- On the first graph, read off the load on the rear
axle as a function of the average deflection
noted.
- On the second graph, read off the output
pressure P2 (corresponds to the pressure
applied to each rear wheel) as a function of the
load value noted from the first graph.
IMPORTANT: each graph corresponds to a
particular make and type of tyre.
10 • Adjusting the compensator :
- Follow the current method described for After
Sales if the compensator is incorrectly set.
37-15