1997 RENAULT KANGOO Chassis Workshop Manual

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.
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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

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
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 ).
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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.
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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

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