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

Master cylinder
Brake servo
Air filter - Brake servo non-return
valve
Vacuum pump
Handbrake control lever
Handbrake control
Brake pipes
Braking compensator
Clutch control cable
Clutch automatic wear take-up
system
External gear control37-1
37-3
37-5
37-6
37-7
37-8
37-10
37-11
37-22
37-23
37-24
Contents
Page
MECHANICAL ELEMENT CONTROLS37
38-1
38-2
38-3
38-4
38-5
38-6
38-7
38-8
38-9
BOSCH ABS
Presentation of BOSCH ABS 5.3
Location of components
Presentation of the hydraulic
regulation assembly
Wiring diagram
Wiring diagram key
31 track connector
Diagnostic socket
Hydraulic assembly
Hydraulic braking test
ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEMS38STEERING ASSEMBLY
Axial ball joint
Manual steering rack
Power assisted steering rack
Gaiter
Steering rack pinion
Manual steering assistance pump
Steering column
36-1
36-3
36-4
36-6
36-7
36-8
36-12
36

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 drum
REFITTING
Remove all dust from the drum and the linings
using brake cleaner.
Fit:
- the drum,
- the washer and the nut, which must be torque
tightened,
- the plug.
Adjust:
- the linings by repeatedly pressing the brake
pedal,
- the handbrake (see section 37 "Controls").
33
33-3

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
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

MECHANICAL ELEMENT CONTROLS
Handbrake control lever
37
REMOVAL
Release the handbrake.
Remove the lower bolts from the exhaust
downpipe.
Remove the rear rubber mounting for the exhaust
pipe.
NOTE : attach the exhaust pipe to the body.
Remove the heat shields.
12998S
98826-2R
Note the handbrake adjustment dimen-
sion,between the end of the nut (1) and the rod.
Slacken nut ( 1 )to release the two cables.
Remove the linkage from the clip (2).
Remove the two handbrake control lever
mounting nuts.
Remove the handbrake lever and disconnect the
connector.
REFITTING
Refitting is the reverse of removal.
Refit the heat shields.
Remember to reconnect the handbrake
connector.
Reset the handbrake control linkage to the
dimension noted on removal.
If necessary, adjust the lever travel (see section
"Adjusting the control").
37-7

MECHANICAL ELEMENT CONTROLS
Handbrake control
37
ADJUSTMENT
Incorrect adjustment of the handbrake where the
cable is too tight:
- prevents the correct operation of the automa-
tic compensation system for the brake shoes ,
- causes long brake pedal travel.
The cables should not be re-tensioned to correct
this fault since it will quickly occur again.
The handbrake should not be used to adjust play,
it should only be adjusted when replacing :
- brake linings,
- cables,
- the control lever.
Any other adjustment except in the above cases is
not permitted.
With the vehicle on a lift supported under the bo-
dy, slacken the nut (1) so the central adjuster is
completely free.
Remove:
- the two rear wheels,
- the two drums.
Check the operation of the compensation system
by rotating the notched sector (D) (ensure it turns
in both directions), then turn it back by 5 to 6
teeth.
98992-1R3
98826-1R
37-8