wheel RENAULT KANGOO 1997 KC / 1.G Chassis User Guide

Spring compressor
FRONT AXLE
Spring and shock absorber assembly
31
Shock absorber base mounting bolt 18
Rebound stop nut 6
Wheel bolts 9
REMOVAL
Put the vehicle on a four post lift.
Remove:
- the wheels,
- the shock absorber base mounting bolts.
NOTE : release the ABS sensor wiring if this is
fitted on the base of the shock absorber.
Remove the upper shock absorber nut in the
engine compartment.
Remove the shock absorber and spring assembly.
TIGHTENING TORQUES (in daN.m)
EQUIPMENT REQUIRED
Replacing a shock absorber
When replacing a shock absorber, fit it in a vice
and compress the spring using the spring
compressor tool.
Remove the spring retaining nut.
Remove the spring and the intermediate parts.
If necessary, replace the shock absorber pad and
the rotating stop.
When refitting, ensure all components are
replaced in the correct location and then
decompress the spring.
NOTE : apply grease between the ends of the
spring and its stops.
REFITTING
Refitting is then the reverse of removal. Observe
the correct tightening torques.
31-9

FRONT AXLE
Engine sub-frame
Remove:
- the two nuts for the steering rack heat shield,
- the mounting nuts for the steering rack and
attach it to the exhaust manifold.
31
12988R
SPECIAL TOOLING REQUIRED
Mot. 1040 -01 Dummy sub-frame for removing/refitting engine/transmission assembly
T. Av. 476 Ball joint extractor
REMOVAL
Disconnect the battery.
Put the vehicle on a two post lift.
Remove the wheels.
Disconnect the track rod ends using tool T. Av.
476.
Remove the key on the stub axle carrier.
Release but do not remove the mudguards to
reach the upper bolt on the sub-frame - side mem-
ber tie rod and remove it.
Remove:
- the exhaust downpipe and attach the catalytic
converter,
- the bolt (engine side) for the engine tie bar.
- the gear control by removing the two bolts at
the ends of the control. To do this, the cataly-
tic converter heat shield must be removed and
the gaiter on the gearbox side must also be re-
moved.
TIGHTENING TORQUES (in daN.m)
Wheel bolts 9
Track rod end nut 3.7
Steering universal joint bolt 2.5
Sub-frame mounting bolt front Ø10 6
rear Ø 12 10.5
Sub-frame - side member tie rod nut 3
Key nut on stub axle carrier 5.5
Engine tie bar 6.5
Steering box mounting bolt 5
Fit tool Mot. 1040-01 under the engine sub-frame.
12993-1R1
31-12

REAR AXLE
Rear axle assembly
TIGHTENING TORQUES (in daN.m)
Bearing mounting nut 11
Wheel bolt 9
Shock absorber base bolt 8.5
REMOVAL
Put the vehicle on a two post lift.
Fit the pedal press.
Remove:
- the two lower shock absorber mountings,
- the brake pipes,
- the compensator control,
- the central heat shield,
- the handbrake cables, disconnecting them
from the central control,
Unclip the cables from the fuel tank.
Support the rear axle assembly and remove the
nuts ( 1 ).
Remove the rear axle assembly.
NOTE : the bolts can be reached under the rear
bench seat (depending on version) after
removing the blanking covers.
REFITTING
Refitting is the reverse of removal.
Bleed the brake circuit.
Adjust the handbrake (see section 37).
Check and if necessary adjust the braking
compensator ( see section 37 ).
33
13132R
33-1

98991
REAR AXLE
Brake drum
Remove:
- the nut and stub axle washer,
- the drum.
The two brake drums must be of the same diameter, if one is reground, the other must also be reground.
Never exceed the diameter marked on the drum.
SPECIAL TOOLING REQUIRED
Emb. 880 Inertia extraction tool
Rou. 943 Hub cover plug extractor
TIGHTENING TORQUES (in daN.m)
Wheel bolts 9
Hub nut 17.5
REMOVAL
Remove the hub plug using tools Rou. 943 +
Emb. 880.
Release the handbrake, slacken the secondary
handbrake cables to allow the lever to move back.
Insert a screwdriver through one of the wheel
mounting holes in the drum and push the hand-
brake lever to release the lug from the brake
shoe( E ).
Help the lever to slacken by pushing it towards
the rear.
33
98990G
33-2

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
Brake linings (drum)
33
REFITTING
Present the assembly to the vehicle.
Attach the handbrake cable to the lever.
Squeeze the bases of the shoes together and
position the other ends on the wheel cylinder
pistons. Take care not to damage the covers.
Position the shoes on the fixed point (C).
Fit the side retainers (3).
Remove the pliers from the wheel cylinder pistons
then refit the lower spring (2).
ADJUSTMENT
Using a screwdriver, adjust the brake shoe
diameter using the notched segment.
Refit the drums without tightening the nuts.
Centre the linings by repeatedly pressing the
brake pedal (approximately 20 times).
Ensure the RAI is operating correctly
(characteristic click from the drums).
Remove the drums.
Ensure:
- the cables slide freely,
- the handbrake levers (L) are correctly
positioned against the shoes.
Progressively tighten the cables at the central
adjustor so that levers (L) start to move between
the 1st and 2nd notch of the control lever travel
and remain applied from the 2nd notch.
Lock the lock nut on the central adjuster.
Refit:
- the drums and tighten the nuts to a torque of
17.5 daN.m,
- the plugs.
98992-3R
33-6

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
Shock absorber
REMOVAL
With the vehicle on its wheels, remove the lower
mounting bolt (1).
Lift the vehicle and remove:
- the wheel,
- the upper mounting bolt (2),
- the shock absorber.
PRECAUTIONS TO BE TAKEN BEFORE FITTING
Shock absorbers are stored horizontally in the
Parts Stores.
Under these conditions it is possible that the shock
absorbers, which are designed to operate in a ver-
tical direction, will have de-primed.
Before fitting the shock absorbers to the vehicle
compress them a few times by hand in the vertical
position.
REFITTING
Fit:
- the shock absorber,
- the upper mounting bolt coated with
MOLYKOTE BR2, without tightening it,
- the wheel.
Lower the vehicle.
Position the lower mounting bolt coated with
MOLYKOTE BR2.
Torque tighten both bolts.
33
Upper mounting bolt 11.5
Lower mounting bolt 8.5
TIGHTENING TORQUES (in daN.m)
13133R
33-8

REAR AXLE
Anti-roll bar, tubular rear axle
TIGHTENING TORQUES (in daN.m)
Bar mounting bolt 5.5
REMOVAL
1Mounting bolt
Put the vehicle on a lift with the wheels hanging
free.
On each side, remove bolts (1) and retain the
captive nuts.
Remove the bar.
REFITTING
On each side, refit the bolts (1) with the captive
nuts.
Tighten to the recommended torque.
33
13132R
33-9