Removal and Installation

RENEW

Remove the rear suspension unit.

Drain the oil from the final drive unit to prevent any leakage from the breather and invert the whole assembly onto a workbench.

Fig.1:

Remove the fourteen nuts, bolts and setscrews (1, Fig.1) securing the bottom tie-plate to the crossbeam and inner fulcrum brackets.

Fig.2:

Remove the nuts and washers securing the dampers to the wishbone and drift out the retaining pins (1, Fig.2). Recover the spacers and tie-down brackets.

Slacken the clips securing the inner universal joint shrouds and slide the shrouds outwards.

Fig.3:

Remove the self locking nuts (1, Fig.3) securing the drive shaft inner universal joint to the brake disc and output shaft flange.

Fig.1a:

Fig.3:

Remove the nut from the inner wishbone fulcrum shaft and drift out the shaft (1, Fig.1a) collecting the spacers, seals and bearings from the wishbone pivots (2, Fig.3).

Remove the drive shaft, hub and wishbone assembly from the rear suspension assembly.

Remove the camber shims from the drive shaft flange studs at the brake disc on both sides.

Remove the spacer tubes from between the lugs of the fulcrum brackets and turn the suspension assembly over on the bench.

Disconnect the brake feed pipes from the calipers, seal the ends of the pipes and the ports in the calipers.

Release the brake return springs from the operating levers.

Fig.2a:

Cut the locking wire and remove the four bolts (1, Fig.2a) securing the final drive to the cross-beam.

Fig.3d:

Lift the cross-beam off the final drive unit (Fig.3a).

Invert the unit.

Fig.4a:

Remove the locking wires and the setscrews securing the fulcrum brackets to the final drive unit (1, Fig.1b).

Remove the brackets, noting the position and number of shims at each attachment point.

Cut the wires from the caliper mounting bolts, remove the bolts and calipers.

Remove the brake discs, noting the number of shims between the discs and the flanges.

Examine all components for wear and damage. Replace worn or damaged components as necessary.

Refit the shims and brake disc on to one output shaft flange and secure with two nuts.

Refit the brake caliper and tighten the mounting bolts.

Check the centering and the run out of the disc. The centering tolerance is 0.25 mm (0.010 in.), and an incorrect reading can be rectified by transferring shims from one side of the disc to the other. The disc run out should not exceed 0.15 mm (0.006 in.).

Repeat the procedure on the opposite side. Remove the nuts from both discs.

Place the cross-beam over the final drive, align and refit the bolts.

Tighten the bolts and secure with new lock wire.

Slacken off the brake feed pipes at the centre union. Unseal the brake pipes and the ports in the caliper, align and fit the pipes and tighten the unions.

Refit the handbrake lever return springs and invent the assembly on the bench.

Position the fulcrum brackets against the final drive unit and locate each bracket loosely with two setscrews.

Refit the shims between the fulcrum brackets and the final drive unit. Tighten the screws and secure with new lock wire.

Refit the camber shims to the drive shaft studs on one side.

Fit the drive shaft on to the studs, loosely fit the nuts, and then fully tighten.

Refit the spacer tube between the lugs of the fulcrum bracket.

Clean, inspect and grease the lower wishbone bearings and thrust washer assembly.

Fig.2b:

Fit new seals and offer up the wishbone fulcrum bracket lugs and locate with dummy shaft service tools JD 14 (1 Fig.2b).

Note: Take great care not to displace any component during this operation.

Drift the dummy shafts from the fulcrum bracket with the fulcrum shaft. Restrain the dummy shafts to prevent spacers or thrust washers dropping out of position.

Fit and tighten the fulcrum shaft nuts.

Re-position the drive shaft shroud and secure it with the retaining clip. Line up the damper lugs with the wishbone bosses and refit the damper shaft, including the spacer and tie down bracket.

Fit and tighten the securing nuts.

Refit the wishbone, drive shaft and damper shaft on the opposite side. Refit the bottom tie-plate.

Fit and tighten the bolts and setscrews.

Refit the rear suspension unit.

Check/adjust the camber angle of the rear wheels.

Bleed the brakes.

Replenish the final drive unit with the correct grade of oil as necessary.

SERVICE TOOLS
JD 14 Dummy shaft

TORQUE FIGURES
Brake caliper mounting bolts 63-77 Nm
Bottom tie-plate bolts 18-24 Nm
Cross-beam bolts 95-105 Nm
Damper securing nuts 41-51 Nm
Drive shaft to output shaft flange 78-94 Nm
Fulcrum bracket bolts 82-88 Nm
Fulcrum shaft nuts 61-67 Nm

OILS/SEALANTS/LUBRICANTS
Differential oil Shell Spirax Super 90