Caterham Seven User Manual download pdf (Page 138)

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Use a jack to lift the differential up from

under the vehicle. This may be easier with

additional help. Hang the differential from

the top mount with a thin/long screwdriver

or tube/rod.

Warnings

1. Never work underneath a car without

supporting it on axle stands or

equivalent. Do not rely on a jack alone.

2. Use appropriate eye protection

whilst working under the car.

Attach the front end of the differential at

the lower mounts; use the M12x55

capheads from the Z-Pack 30Z1067A

(copper slip the shank). Take care to use

M12 Schnorr washers underneath the

head of the bolt. Attach the bolts loosely

as you will need to centralise the

differential in the next stage.

Figure 123: Differential installation and

LHS

1. ½” nyloc nut with schnorr washer

2. Cable tie and handbrake cable

3. M12 x 55 with schnorr washer

Measure from either side of the differential

carrier to the outboard side of the chassis

(outboard of rear ARB mount – 1” BOX) to

centralise. During this process there will

be a need to pull the bottom bolts out and

use shim washers (item 21 in pack

30Z1067A) inserted in between the

metalastic bush and carrier as necessary.

You may now use the ½ x 11” top bolt

(schnorr washer under the head). It is

optional to grind a chamfer on the end of

the bolt (threaded part 45 degrees x ½”)

as this makes it easier to slide and locate

the top bolt. Ensure there is plenty of

copper slip used on the bolt. You will also

need to space the upper bolt between the

carrier and the metalastic with shim

washers. Use a ½” nyloc nut and schnorr

washer to fasten the bolt.

Torque the top and bottom bolts to 60Nm.

The driveshaft flanges can now be

removed into the differential. This is done

by using a bar and levering them out of

the main case.

The driveshafts can now be inserted into

the differential and the suspension fitted.

Please ensure that the handbrake cable

on the LHS does not sag down to the

driveshaft. Utilise the holes on the side of

the diff carrier and cable tie in place.

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