Reliant Kitten Estate, Workshop Manual

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Page 71
Figure 15 Replacing the differential bearing using special tool and
universal handle
1. Replacer tool
2. Universal handle
6. Measure the gap between the gauge nut and the disc and
record the figure. This figure represents the amount of shims, taking
in to account the bearing width variation plus the manufacturers'
preload, that must be fitted to the right-hand differential carrier
bearing. The remainder of the shims from the overall end-float, taking
in to account again any variation in bearing width, will be fitted to the
left-hand or pinion side of the differential.
Example
To give correct backlash, shims required on right-hand side equals
0.030. therefore shims on right hand side will be 0.050 minus 0.030
equals 0.020. These figures have been obtained using the dummy
bearings. Separate the axle cases, remove the differential and proceed
as follows:
Measure and compare each dummy bearing with the overall width of
the new taper bearing assembly to be fitted on each end. Ensure that
the rollers are settled by rotating before measurement. The plus
readings from the dummy bearings width are subtracted from the
selected shims. The minus readings are added to the selected shims.
Right-hand side
Dummy bearing width example 0.710
Taper bearing width example 0.715
Actual shims required 0.30 minus 0.005 = 0.025 plus 0.002 which
represents the manufacturers' preload allowance. Therefore total
shims required = 0.027.
Left-hand side
Dummy bearing width example 0.712
Taper bearing width example 0.710
Actual shims required 0.020 plus 0.002 = 0.025 plus 0.022 which
represents the manufacturers' preload allowance. Therefore total
shims required = 0.024.
Operation 8 Final re-assembly of axle
1. Tap both the differential bearing outer tracks in to the two
halves of the axle case.
2. Replace the correct shims on the differential unit. Using a
hide mallet and tool number RT 550.1 and universal handle 550,
replace the differential unit bearing (
Figure 18 )
Figure 16 Modification of gauging tool RT 8732
3. Place the differential unit in to the differential case housing.
4. Replace the left-hand half shaft to assist in supporting the
crown wheel and differential assembly.
5. Secure the two halves of the axle case together using
Hylomar jointing compound and secure with the eight nuts and lock
washers to a torque of 2.76 - 3.46 kg/m (20 - 25 lb/ft).
6. Refit the right-hand half shaft complete with hub bearing to
engage in the differential unit.
7. Check that the total torque to turn the pinion flange is
0.265 to 0.334 kg/m (23 to 29 lb/in)
8. Locate the right-hand back plate and brake assembly to the
axle end, positioning the back plate spacer and insert against the back
plate. Align the holes and secure with the three set screws and lock
washers. Ensure that the insert is free to move in the spacer aperture.
9. Clean the taper of all grease and foreign matter.
10. Position the hub key in its location and fit the hub.
11. Secure the hum to the half shaft with the nyloc nut and
washer tightening to a torque of 13.8 - 15.2 kg/m (100 - 110 ft/lb).
12.
Repeat the operations for the left-hand hub, back plate and
brake assembly.
13. Refit the axle unit on the vehicle (see previous axle
replacement procedure)
14. Reconnect the hydraulic brake pipes.
15. Check the brake drum faces are clean and refit the brake
drums and wheels.
16. Adjust the brakes and bleed the brake system.
17. Top up the axle with the recommended lubricant.
18. Tighten the level/filler plug to 2.07 to 2.76 kg/m (15 to 20
ft/lb)
Modification of gauging tool RT 8732
The tool, originally intended for Robin axles, requires the drilling of
two additional 11/32 in holes in the circular plate. The tool will then
accommodate both Robin and Kitten axles.
It is suggested that a template is made as shown in
Figure 16 to
ensure accurate drilling of the plate.