Removal and Replacement
Bevel Box
Removing
- Lift the vehicle, all 4 lift points of the hoist must be at the same height.
- Turn the steering wheel to the center position.
- Move the selector lever into the "P" position.
- Remove the ignition key and engage the steering wheel lock.
- Loosen the right drive axle bolt - arrow -.
• Do not place the vehicle on the floor after loosening the bolt.
• To make it possible to rotate the driveshaft later so it can be loosened:
- Move the selector lever into the "N" position.
- Remove the ignition key and engage the steering wheel lock.
- Remove the noise insulation below the engine/transmission.
- Remove the right drive axle.
- Remove the right drive axle heat shield bolts and shield.
- Remove the flexible disc shield bolts - arrows - and shield.
The bolt - arrow A - is installed to the transmission carrier.
- Remove the pendulum support bolts - 1 and 2 -.
- Mark the position of the driveshaft flexible disc to the bevel box output flange.
- Counter hold the rear final drive to loosen and tighten the driveshaft.
• To loosen the next bolt, rotate the driveshaft by turning the rear wheels.
- Remove the driveshaft flexible disc bolts - arrows - from the output flange.
- Guide the driveshaft upward into the tunnel and support it on the steering gear shield using a suitable wooden block.
- Remove the transmission carrier stud bolts/bolts - 1, 2 and 3 -.
- Remove the top bevel box to transmission bolts - arrows -.
- Remove the bottom bevel box to transmission bolts - arrows -.
- Press the engine and transmission forward by hand and secure them in this position with a suitable piece of wood - A -.
- Carefully press the bevel box off the transmission and remove it downward.
Installing
Install in the reverse order of removal. Note the following:
- Grease the splines on the differential using grease for clutch plate splines (G 000 100).
- Install a new circlip - arrow A - and a new O-ring - arrow B - on the right flange shaft.
- Insert the bevel box and press it against the transmission until seated.
• If the tooth position is incorrect (the bevel box cannot be pressed against the transmission), rotate at the flange shaft.
- If the tooth position is correct and it is guided centered, the bevel box slides against the transmission until seated.
Hit the flange shaft circlip onto the toothed lug with a plastic hammer on the front side to make sure it latched correctly into the differential bevel gear. Do not pull the bevel box forcefully against the transmission by tightening the bolts. The transmission or bevel box could be damaged.
- First, tighten the bevel box with new bolts - arrows - hand tight, then tighten them to specifications. Tightening specification: 40 Nm + an additional 90° (1/4) turn.
- Install the transmission carrier. Follow the installed location and tightening sequence for the bolts.
Installed Location
Tightening Sequence
- Check the gear oil level in the bevel box. Refer to => [ Bevel Box Gear Oil, Checking and Filling ] Procedures.
- Install the drive axle heat shield and bolts.
- Move the engine and transmission forward and remove the wooden block - A -.
- Position the driveshaft to the bevel box by pressing the engine/transmission assembly forward as far as necessary.
• The seal in the driveshaft flange - arrow - must not be damaged when removing and installing the transmission. Replace the driveshaft if it is damaged.
- Install the driveshaft flexible disc bolts - arrows - to the output flange.
- Tighten the pendulum support with new bolts.
- Grease the flange shaft splines with grease for clutch plate splines (G 000 100).
- Install the right drive axle.
- Install the exhaust system.
- Install the noise insulation.