Chassis Limit From 465399

Pinion seal, angle gear, replacement

Special tools:
998 7693
999 5069
999 5304
999 5504
999 5561
999 5652
999 5653
999 5743

Note! Check that the parking brake is not applied and that no gear is engaged.

Removing the propeller shaft from the angle gear

Marking the driver




Note! Follow the instructions carefully. Position the lifting arms in accordance with Towing, changing wheels and rolling road / wheel spinner test.

- Raise the car.
- Mark the universal joint with a line level with the angle gear driver.

Remove the propeller shaft screws



- Remove the propeller shaft screws. Use counterhold 999 5743 .

Removing the screws to the bracket and support for the propeller shaft.



Remove the two screws:
- to the bracket for the center bearing for the propeller shaft, from the support (removed in the illustration)
- Undo the support's screws on the left-hand side. Remove the screws on the right hand side (removed in the illustration)
- Move the propeller shaft to the right, tie it up at the front and rest it on the support

Removing the nut to the angle gear driver

Mark up
- the driver and nut in relation to the pinion shaft end.

Remove
- Remove the nut.



- Use counterhold 999 5652 including fitting ring 999 5744 .

Removing the driver and spacing sleeve for the pinion

Remove:
- the driver. Use puller 999 5304.



- the pinion spacing sleeve. Use puller 998 7693 or a universal puller.
Collect any oil in a container.

Removing the seal



Remove the seal
- Use puller 999 5069 .

Note! Carefully check that no residue from the old seal remains. In addition, check that the sealing surface on the pinion spacing sleeve is unblemished.

Installing the seal

Fit the seal:
- Lubricate the lip of the sealing ring with wheel bearing grease, part no. 1161241-3. Fit the seal on the drift 999 5653 against the side on the tool marked 1155.

Press in the seal



- Use press tool 999 5504 .

Installing the pinion spacing sleeve and driver

Install:



- the pinion spacing sleeve and driver in accordance with prior marking If necessary, use press tool 999 5504 .

Fitting the nut for the driver

Note! Striking nut runner must not be used.

Install:



- the marked nut. Tighten to 180 Nm . Use counterhold 999 5652 including fitting ring 999 5744 . No axial play may be present.

Check marking:
- on pinion nuts to the pinion shaft Pull so that the marking on the pinion nut passes the marking on the shaft by 5-10�. If necessary increase the torque to achieve this.

Note! 200 Nm must not be exceeded. The pressing on the pinion bearings can become too hard and cause failure.

Installing the propeller shaft to the angle gear

Note! Fit the propeller shaft in accordance with prior marking and with the center joint in front of the center bearing. Check that the contact surfaces on the viscous clutch and propeller shaft drivers are clean.

Fit the propeller shaft to the driver.



Propeller shaft location
Position the propeller shaft so that the center joint is in front of the center bearing. There is a risk that the propeller shaft can be incorrectly turned 180� as the difference in length is only 13 mm between the front and rear section. On the front propeller shaft is a manufacturer label with the text "Front side". The label can become illegible or fall off.

Installing the center support and the center bearing bracket.
Installation



- Fit the center bearing support to the body. Press to the left and tighten to 25 Nm .
- Fit the center bearing bracket to the support. Tighten to 25 Nm .

Torque tightening the screws in the universal joint
Use new screws.



- Tighten screw (1) and (2) in numerical order to 10 Nm as per the illustration (A).



- Tighten screws (1) to (6) in numerical order as per the illustration (B) to 25 Nm and finally screw (1) again.



- Use counterhold 999 5743 .

Right-hand drive cars:



Note! On right-hand drive and early lefthand drive cars the oil level plug is difficult to reach.

Remove:
- The collision protection system

Check the oil level
- The oil must reach the level plug lower edge. Fill with oil if necessary.

If the oil level reaches the level plug lower edge.
- Refit the plug, tighten to 35 Nm.
- Refit the collision protection system, tighten to 80 Nm.

Left-hand drive cars with early model vibration damper: (Up to and including chassis no: 318612)



Remove:
- The vibration damper

Check the oil level
- The oil must reach the level plug lower edge. Fill with oil if necessary.

After checking the oil level:
- Fill with oil as required and refit the plug, tighten to 35 Nm.
- Refit the vibration damper, tighten to 25 Nm.

Left-hand drive cars with later model vibration damper: (From and including chassis no: 318613)

Check the oil level in the angle gear
- The oil must reach the level plug lower edge. Fill with oil if necessary.