Reliant Kitten Estate, Workshop Manual

Page: 64 / 138

Page 64
Section K
Contents
Description
Routine maintenance
Operation 1 Rear axle - removal and replacement
Operation 2 Replacing half shaft bearings
(axle in vehicle)
Operation 3 Dismantling rear axle
Operation 4 Re-assembly - determining overall
differential end float
Operation 5 Re-assembly - setting the pinion
Operation 6 Re-assembly - Installation of pinion in axle case
Operation 7 Re-assembly - determining correct backlash,
crown wheel to pinion
Operation 8 Final assembly of axle
Description
The rear axle is of the spiral bevel gear, semi floating type, the saloons
and estates having a ratio of 3.23:1. The van models have an axle ratio
of 3.545:1.
A two piece axle case assembly houses a taper roller bearing
differential unit with the crown wheel bolted to the casting.
The pinion is located in the centre of the housing case supported by
taper roller bearings.
Bearing preload in the differential assembly is controlled by shims
between the bearings and the differential castings.
The depth of mesh between the pinion and the crown wheel is
controlled by a spacing washer and additional shims as required.
The crown wheel and pinion are a selected pair. Identifying numbers
are etched on both. This condition applies to spare parts and
production alike. Under no circumstances should an unmatched
crown wheel and pinion be fitted.
Routine maintenance
Top-up the rear axle every 6,000 miles (10,000 km) if necessary. The
rear axle oil level should be checked by means of the combined
filler/level plug (
Figure 2 ).
The axle does not have a drain plug. The initial oil fill and the
recommended oil for topping up the rear axle are formulated to give a
sludge-free axle life.
Note: The rear axle has a breather hole, located in the left-hand axle
tube and this should be checked and cleaned out, if necessary, every
6,000 miles (10,000 km). If the breather hole is continually blocked,
pressure generated within the axle will cause oil leakage from the
pinion and half shaft seals.
Operation 1 Rear axle- removal and replacement.
To remove
1.
If a ramp is not available jack up the car and place securely
on axle stands under the chassis rails. Remove the road wheels.
Rear axle
2.
Remove the drive (prop) shaft see Section J.
3. Disconnect the handbrake cables from the operating levers
on the brake back plates by removing the split pins and washer and
withdrawing the clevis pins. Disconnect the cables from the stop
brackets on the axle tubes.
4. Disconnect the hydraulic flexible pipe from the three way
connector on the axle tube and plug both this and the three way
adapter to stop fluid leakage and dirt ingress.
5. Place a jack or suitable support under the axle.
6. remove the nuts and washers and disconnect the lower
damper mountings, freeing the dampers from the axle.
7.
Unscrew the 8 locknuts and 8 nuts and washers from the
"U" bolts securing the leaf springs to the axle.
8. The axle unit can now be lowered from beneath the vehicle
and removed.
To refit
1.
carefully raise the rear axle until it locates on the pegs on
the springs.
2. Secure the axle to the leaf springs with four "U" bolts,
washers, nuts and lock nuts.
3. Refit the damper units to the axle mounting.
4. Replace the drive (prop) shaft.
5. Reconnect the hydraulic flexible pipe to the three way
connector on the axle tube.
6.
Locate the handbrake cables in to the stop brackets and
reconnect the cables to the levers on the back plates with washers,
the clevis pins and new split pins.
7. Refit the road wheels and bleed the brakes.
Operation 2 Replacing half shaft bearings
(axle in vehicle)
1. If a ramp is not available, jack up the vehicle, place suitable
stands under the chassis and remove the road wheels.
2.
Disconnect the hydraulic brake pipes from the brake back
plates.
3.
Disconnect the handbrake cable from the operating arm by
removing the split pin and washer followed by the clevis pin.
4.
Slacken the brake adjuster and remove the brake drum.
5. Unscrew the half shaft nut complete with washer, whilst
preventing the hub turning by using a lever wedged between two
studs, or a plate tool as shown in
Figure 3 .
6. A hub puller, part No. RT 8090 is necessary to remove the
hub. Fit hub puller sleeve on to the end of the half shaft ( Figure 4 ), to
prevent damage. If the sleeve is not available, refit the nut and screw
until the top face of the nut is level with the end of the half shaft.
7.
Secure the hub puller to the hub using all four wheel nuts,
tightened securely.
8.
Tighten the hub puller to release the half shaft taper.
9. Remove the hub puller and sleeve and withdraw the hub.
10. Unscrew three set screws and washers and remove the
brake back plate.
11.
The half shaft is removed by using a slide hammer part No.
RT 3072 and adapter RT 3072-2. Fit the adapter on to the slide
hammer and screw on to the half shaft. Sliding the hammer away
from the axle will release the half shaft from the axle and the shaft,
complete with slide hammer, can be withdrawn from the axle tube as
shown in Figure 8