Reliant Rebel 700 1967 Workshop Manual page 61

finally clamping the plate. The two round knurled gauging nuts should
be screwed on to the push rod, which is facing the crown wheel or
pinion side of the crown wheel which, for convenience of explanation,
should be on the left-hand side
Figure 10 Measuring the torque to turn the pinion using dummy
Pinion tool
1. Pinion setting tool
of the operator as they face the axle and referred to as the left-hand
side throughout these instructions.
5. Unscrew the right-hand side push rod approximately 3.2
mm (1/8 in). Screw in the left-hand push rod with a load of 2-4 lb/ft
maximum, thus pushing the differential assembly over in to the right-
hand housing. Screw up the gauging nut lightly to the face of the
circular plate. Carefully screw the locking nut up to the gauging nut
and screw the push rod back approximately 3.2 mm (1/8 in), ensuring
the gauge nuts move with the screw as they come away from the
plate. Screw in the right-hand push rod 2-4 lb/ft maximum, thus
pushing the differential unit in to the left-hand axle housing. Screw in
the left-hand push rod until a stop is felt. Measure the gap between
the circular plate and the gauge nut with a feeler gauge and record
the figure (Figure 9) which will represent the overall end float.
6. Separate the casings and remove the differential assembly
complete with dummy bearings , but Do not remove the dummy
bearings from the differential carrier.
Re-assembly - setting the pinion
1. Ensure the pinion bearing cups are seating correctly in the
pinion housing.
2. Locate the thick pinion spacer washer on the dummy pinion
RT 8730 followed by the taper bearing cone.
3. Locate the dummy pinion in the pinion housing, placing the
outer bearing cone in position, followed by the flange and the dummy
pinion nut and tighten to give the running preload, thus setting the
rollers.
4. Place the mandrel, RT 8730 in the differential side bearing
bore. With a dial gauge torque wrench, check the torque required to
turn the dummy pinion nut (Figure 10). This should read 0.115 to
0.150 kg/m (10 to 13 lb/in) torque without the oil seal, 0.150 to 0.184
kg/m (13 to 16 lb/ft) with the oil seal. Ensure that the mandrel is
seating correctly and measure with feeler gauges the gap between the
outside diameter of the mandrel and the dummy pinion face (Figure
11). Any amount in excess of 0.030 in will be the spacers required to
bring the pinion to its correct operating distance. take in to account,
when determining the shims required, any figure stamped on the
pinion itself, which represents any variation in manufacture from the
nominal mounting distance i.e. if a figure of 0.003 is stamped on the
Figure 11 Determining pinion mounting distance using dummy
pinion
Figure 12 Replacing pinion bearing cone using hand press and collars
1. Collars
2. Adaptor
3. Spacing washer
pinion shank, this means it has been manufactured high and requires
reducing in height by the same distance. Therefore if the gap
measured is, say 0.044, the spacers required will be 0.44 minus 0.030
minus 0.003 which will equal spacers to the value of 0.011 thicker
than that used for measurement.
5. Remove the dummy pinion assembly, place the selected
spacer on the pinion and assemble the bearing cone, using the hand
press tool No. 47, adapter RT 8765/2 and bearing replacer collars RT
8765/1 (Figure 12)
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