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Home >> Volvo >> 2000 >> S70 AWD L5-2.4L Turbo VIN 56 B5244T >> Repair and Diagnosis >> Transmission and Drivetrain >> Transfer Case >> Service and Repair >> Bevel Gear, Replacing, AW42 AWD >> Chassis Limit From 465399

Chassis Limit From 465399



Bevel gear, replacing

Special tools:
- 999 5562
- 999 5563

Note! Follow the instructions on positioning the lift arms carefully. See Towing, changing wheels and rolling road / wheel spinner test.

Removing bevel gear

Removing the front wheel



Remove:
- the right front wheel
- the screw for the brake hose bracket. Unhook the bracket
- the ABS sensor. Hang up the sensor.

Note! Do not disconnect the connector.

- the screw for the drive shaft. Counterhold the brake disc. Use a screwdriver.

Removing the control arm and ball joint



Remove:
- the nut for the anti-roll bar link. Unhook the link
- the wheel spindle - ball joint screw.
- Remove the ball-joint from the wheel spindle.
- Install the protective socket 999 5562 on the ball joint.

Installing the control arm holder



Press
- the drive shaft into its inner position. Turn and fold out the spring strut.

Remove
- the drive shaft from the hub.

Removing the drive shaft



Remove:
- the bearing cap for the drive shaft
- the shaft. Carefully pull the shaft straight out from the transmission so that sealing ring is not damaged.

Removing the vibration damper and the support bracket

Remove:
- the vibration damper for the bevel gear, 3 nuts and the limiter from the sub-frame
- the support bracket between the exhaust pipe and the bevel gear
- the holder for the oil pipe



- Slacken off screw 1 slightly, so that the power steering pipe can be bent to one side when the bevel gear is taken down.

Bending the oil cooler to one side

Carry out
- Position a container under the oil cooler



- Remove the four screws retaining the oil cooler
- Push the oil cooler to one side.

Note! A small amount of oil will run out.

Disconnecting the propeller shaft from the bevel gear

Marking the flange

Note! Follow the instructions carefully. Position the lift arms according to Towing, changing wheels and rolling road / wheel spinner test .

- Raise the car.



- Mark the propeller shaft CV joint with a line at the height of the flange for the bevel gear.

Slacken off the screws
- Slacken off the screws for the propeller shaft.



- Slacken off the screws to halfway. Use counterhold 999 5743 .

Secure the screws

Securing the flange screws



Secure the screws using a steel wire as illustrated. Check that the position of the screws in the propeller shaft CV joint cannot changed. Slacken off the screws so that the threads are released but allow them to remain in the constant velocity joint.

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 the 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 bevel gear

Remove
- the 5 screws holding the bevel gear
- Lift the bevel gear down.

Installing the bevel gear

Note! Before installing the bevel gear, lubricate the spline joint between the transmission and the bevel gear using grease.

Install the bevel gear



- Check that the coupling sleeve between the transmission and the bevel gear is in place
- Ensure that the mating surfaces are clean
- Install the screws
- Do not forget the exhaust pipe bracket
- Lightly tighten the screws crosswise. Then tighten to 50 Nm .

Installing the oil cooler



- Install the oil cooler. Tighten to 17 Nm .

Installing limiter and vibration damper



Install:
- the deflection limiter. Tighten to 20 Nm
- the vibration damper. Tighten to 20 Nm
- The holder for the oil pipe. Tighten to 35 Nm
- Tighten screw 1 to 25 Nm .

Installing the propeller shaft on the bevel gear
Carry out corrective action. See Installing the propeller shaft to the angle gear

Installing the drive shaft on the support bearing mounting
- Install the drive shaft on the support bearing mounting



- Tighten the bearing cap screws. Tighten to 25 Nm .

Installing the drive shaft on the hub

Install the drive shaft on the hub



- Use holder 999 5563 to hold the control arm down
- Fold out and turn the spring strut. Align the drive shaft in the hub
- Install the drive shaft screw by hand. The old screw can be reused. Lubricate the screw
- Remove the holder.

Note! Take care not to damage the drive shaft boot.

Installing the control arm and ball joint



Reinstall the control arm and ball joint on the wheel spindle
- Remove protective sleeve 999 5562 from the ball-joint.
- Check that the groove on the ball joint spindle lines up with the screw hole in the wheel spindle.
- Use a new lock nut. Tighten to 50 Nm .

Tightening the screw for the drive shafts



Tighten:
- the drive shaft screw. Tighten to 50 Nm
- Counterhold the brake disc. Use a screwdriver.

Installing the bracket and ABS sensor



Install:
- the bracket for the brake line and ABS cable
- the ABS sensor on the wheel spindle.
- Clean the sensor with a soft brush.
- Lubricate the sensor holes with wheel bearing grease, P/N 1161241-3.

Note! Ensure that the sensor seat is absolutely clean.

- Tighten the sensor. Tighten to 10 Nm
- Install the wheel. Tightening the wheel studs .
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