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

Brake fluid
78491R
GENERAL
Brake unions and pipes
30
The connection of the pipes between the master
cylinder, calipers, compensator and the hydraulic
assembly is made using threaded unions with a
METRIC THREAD.
Consequently, only parts specified in the Parts
Catalogue for this vehicle should be used.
Identification of parts
- SHAPE of the ends of PIPES in steel or copper
(A),
- SHAPE of the THREADED LOCATIONS on
components (B),
- pipe UNIONS coloured GREEN or BLACK:
HEXAGONAL OUTSIDE 11 mm or 12 mm (C).
BRAKE FLUID RENEWAL FREQUENCY
Braking technology, in particular for disc brakes (hollow pistons which transmit little heat, low volume of
fluid in the cylinder, sliding calipers avoiding the need for a fluid reservoir in the least cooled area of the
wheel), has allowed us to avoid the risk of vapour lock as far as possible, even if the brakes are used
intensively (in mountainous areas).
Modern brake fluids still degrade slightly during the first few months of use due to a small uptake of
humidity and replacement of the fluid is therefore recommended (refer to vehicle’s Warranty and Servicing
Handbook).
Topping up the level:
Wear of the brake pads and shoes will cause a gradual drop in the fluid level in the reservoir. This drop should
not be compensated for since the level will rise again when the pads are changed. The level should not
however be allowed to fall below the minimum mark.
Approved brake fluids:
Mixing two incompatible brake fluids in the circuit will cause a risk of major leaks, mainly due to
deterioration of the cups. To avoid such risks, it is important to use only those brake fluids which have been
tested and approved by our Technical Department and which conform to standard SAE J 1703 dot 4.
30-9

FRONT AXLE
Front brake calipers
31
REPAIR
NOTE :
if there are any scratches in the caliper
bore, the complete caliper must be replaced.
To do this:
- remove the brake caliper,
- remove the rubber dust cover,
- remove the piston using compressed air,
inserting a wooden block between the caliper
and the piston to prevent damage to the
piston: any trace of damage to the piston skirt
will render it unusable
- remove the seal from the caliper groove using
a flexible rounded edge blade (eg feeler
gauge).
Clean the parts using methylated spirits.
Replace any faulty parts using original parts and
then refit the seal, piston and dust seal.
REMOVAL
In the passenger compartment, fit a pedal press
(limits the amount of brake fluid which will run
out).
Release the brake pipe at the wheel cylinder end.
Remove the brake pads (see previous page).
Remove the two mounting bolts for the caliper on
the stub axle carrier.
Completely release the brake pipe by turning the
caliper.
Check the condition of the pipe and replace it if
necessary.
REFITTING
Fit the pipe onto the caliper.
Remove the pedal press.
To check the correct operation of the caliper
cylinder, slacken the bleed screw and wait for
brake fluid to run out.
Retighten the bleed screw.
Refit the caliper on the stub axle carrier and
tighten the bolts to the recommended torque.
Refit the pads and the wheel cylinder (follow the
method described previously).
Wheel bolts 9
Brake caliper guide bolt 4
Brake caliper mounting bolt 10
TIGHTENING TORQUES (in daN.m)
31-5

FRONT AXLE
Stub axle carrier bearing
31
SPECIAL TOOLING REQUIRED
Rou. 15 -01 Shaft protector
Rou. 604 -01 Hub locking tool
T.Av.476 Ball joint extractor
T.Av. 1050-02 Tool for pushing driveshaft back
Driveshaft nut 28
Wheel bolts 9
Shock absorber base nut 18
Brake caliper mounting bolt 10
Track rod end nut 3.7
Key nut on stub axle carrier 5.5
83348G
REMOVAL
Disconnect the battery.
Remove:
- the wheel,
- the brake caliper and attach it to the spring so
the pipe is not damaged,
- the track rod end using tool
T.Av. 476,
- the driveshaft nut.
Push back the driveshaft using tool :
T. Av. 1050-02.
Remove:
- the brake disc,
- the lower ball joint nut and key,
- the two shock absorber base bolts,
- the hub / stub axle carrier / bearing assembly.
TIGHTENING TORQUES (in daN.m)Remove the hub on the press.
Remove the lower bush from the hub using an ex-
tractor with jaws and tool Rou. 15-01.
Remove the locking spring ring from the stub axle
carrier.
On the press remove the remainder of the bea-
ring, taking care to take the weight on the inner
bush using a tube of the same diameter.
31-7

FRONT AXLE
Stub axle carrier bearing
31
79057S
REFITTING
Fit the bearing on the press, into the stub axle car-
rier using a tube of external diameter
70 mm and bore 66 mm, taking the weight on the
external bush.
IMPORTANT: do not take the weight on the inter-
nal bush to avoid damaging the bearing as the
force required to push the bearing on is quite
considerable.
79058-1S
Fit a new locking spring ring.
Coat each sealing lip of the bearing with multi-
purpose grease.
Fit on the press, using a tube of external diameter
48 mm and internal diameter 42 mm, taking the
weight on the inner bearing bush.
85902S1
Refit the hub / stub axle carrier / bearing assembly
to the vehicle.
Refitting is then the reverse of removal. Observe the
correct tightening torques.
31-8

FRONT AXLE
Anti-roll bar
31
- the central bearing bolts using tool
Sus. 1413.
12991R
- the two sub-frame reinforcements,
- the lower bolts on the exhaust downpipe.
Rubber bush locking position :
UNLADEN.
31-11

FRONT AXLE
Engine sub-frame
31
Lower the lift until the tool touches the ground.
Remove the sub-frame mounting bolts.
Carefully raise the lift.
REFITTING
Systematically renew the engine sub-frame moun-
ting bolts and ensure they are tightened to the
correct torque.
Refitting is the reverse of removal.
NOTE : the engine sub-frame is fitted to the body
in the following manner.:
- fit 2 pins in place of the front mounting bolts,
- offer up the sub-frame,
- tighten, but do not lock, the rear mounting
bolts (begin with the longest rear right hand
bolt),
- replace the pins with mounting bolts at the
front,
- tighten the four mounting bolts to the correct
torque, beginning at the rear,
- ensure the heat shields are correctly refitted.
31-13

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
Four bar rear axle
SPECIAL TOOLING REQUIRED
Emb. 880 Inertia extractor
TIGHTENING TORQUES (in daN.m)
Upper shock absorber mounting 8.5
Lower shock absorber mounting 11.5
Wheel bolts 9
REMOVAL
Remove:
- the wheels,
- the shock absorbers,
- the suspension bar plugs.
Remove using tool Emb. 880 :
- the two suspension bars,
- the two anti-roll bars, retaining the central
shackle.
Clean and lubricate the bar splines using
MOLYKOTE BR2.
REFITTING
The anti-roll bars cannot be removed from the
vehicle when the shock absorber replacement tool
is in position. Because of this, and to make it
easier to refit the shackle, a wooden block must
be made according to the diagram below.
Fit:
- the shackle on the block (locally made) in the
centre of the rear axle assembly,
33
13135R
Dimensions in mm and degrees ( ° ).
33-17

REAR AXLE
Four bar rear axle
- the first anti-roll bar, ensuring the angle of
the block is observed, and the bar is inserted
freely.
33
13134S
- the second anti-roll bar, ensuring it engages
freely.
In order to position the suspension arm so that the
bar may be correctly positioned, a tool must be lo-
cally made.
ANut, diameter 14 mm
BNut, diameter 12 mm
CThreaded rod, diameter 12 mm - length 660
mm
DBracket from flat sheet 30 x 5 mm
E 12 x 60 mm bolt, cut to a length of 20 mm
FWeld
75505-1R1
88637R2
Preset the tool to obtain dimension "X".
X = 430 mm
Fit the tool in place of the shock absorber.
Refit:
- the bar plugs,
- the shock absorbers,
- the wheels.
Put the vehicle on its wheels and measure the un-
derbody heights ( see section "values and set-
tings" ).
33-18