Chassis Limit Up to 465398

Replacing the pinion seal for the bevel gear

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

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

Marking the propeller shaft and flange
- Mark up the propeller shaft constant velocity joint in relation to the bevel gear flange
- Remove the screws for the propeller shaft



- Use counterhold 999 5561.
- The tool must modified according to the Workshop Guide Bulletin.

Removing the screws from the bracket and cross-member for the propeller shaft
- Remove the two screws for the center bearing bracket for the propeller shaft from the member (removed in illustration)



- Remove the screws for the member on the left-hand side. Remove the screws on the right hand side (removed in the illustration)

- Push the propeller shaft to the right. Tie the shaft at the front end and let it rest on the member

Removing the nuts for the bevel gear flange
- Mark the position of the flange and nut in relation to the pinion shaft end
- Remove the nut



- Use counterhold 999 5652.

Removing the flange and the spacer sleeve for the pinion

Remove:
- the flange. Use puller 999 5304



- the pinion spacer sleeve. Use puller 998 7693 or a universal puller.

- Use a container to collect oil spillage.

Removing the seal



- Remove the seal Use puller 999 5069 .

Note! Check that no seal residue is left. Check that the sealing face on the pinion spacer sleeve is OK.

Installing the seal
- Lubricate the sealing ring lip. Use wheel bearing grease, P/N 1161241-3. Install the seal on drift 999 5653 against the side of the tool marked 1155.



- Press in the seal Use press tool 999 5504.

Installing pinion spacer sleeve and flange
- Install the spacer sleeve and flange for the pinion according to the markings made earlier



- If necessary, use tool 999 5504.

Installing a new nut for the flange

Note! Do not use a pneumatic air hammer.

- Install the marked nut.



- Tighten to 180 Nm . Use counterhold 999 5652 .
- There must be no axial play.

- Check the marking for the pinion nut against the pinion
- The marking on the pinion nut must have passed the marking on the pinion by 5-10�. If necessary increase the torque to achieve this.

Installing the propeller shaft on the bevel gear
- Install the propeller shaft according to on the bevel gear flange
- Use new screws.
- First tighten the screws crosswise. Tighten to 8 Nm.
- Then tighten to 30 Nm. Start tightening with the same screw both times.



- Use counterhold 999 5561. The tool must modified according to the Workshop Guide Bulletin.




Installing the center bearing member and the center bearing bracket
Install:
- the support for the center bearing on the car body. Tighten to 25 Nm
- the bracket for the center bearing on the member. Tighten to 25 Nm .

Checking the oil level in the bevel gear
- Only use transmission oil with P/N 116 1618-2 (1000 ml).

Right-hand drive cars:



The oil level plug is difficult to access on right-hand drive and early left-hand drive cars. See the method below

Remove:
- The collision protection system.

Check the oil level

After checking the oil level:
- Reinstall the plug. Tighten to 35 Nm
- Reinstall the collision protection system. Tighten to 80 Nm .

Left-hand drive cars with the early type of vibration damper: (before chassis no.: 318613)



Remove:
- The vibration damper.

Check the oil level

After checking the oil level:
- Reinstall the plug. Tighten to 35 Nm
- Reinstall the vibration damper. Tighten to 25 Nm.