Chassis Limit Up To 465398
Bevel gear, replacing
Special tools:
- 951 2050
- 999 5540
- 999 5561
- 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 nut for the drive shaft. Use counterhold 999 5540 . Tap the end of the drive shaft 10-15 mm into the hub. Use a copper or rubber mallet.
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 sleeve 999 5562 on the ball joint.
Installing the control arm holder
- Install holder 999 5563 to hold the control arm down
- 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 bevel gear vibration damper and the limiter from the sub-frame
- the support bracket between the exhaust pipe and the bevel gear.
Marking the flange
- Mark the position of the propeller shaft flange in relation to the bevel gear flange
Note! Mark up only if reinstalling the bevel gear.
- Remove the screws for the propeller shaft, use counterhold 999 5561
- Modify the counterhold according to Tool Bulletin.
Removing bevel gear
- Remove other screws holding bevel gear.
- Lift down the bevel gear
Installing the bevel gear
Install the bevel gear
Make sure the joint between the bevel gear connecting sleeve and the sealing ring on the gearbox is not leaking and that the sleeve is otherwise free from damage and is in the correct position.
- Ensure that mating surfaces are clean.
- Install the screws.
- Do not forget the exhaust pipe bracket.
- Lightly tighten the screws crosswise. Then tighten to 50 Nm .
Note! When replacing the bevel gear: The bevel gear is supplied filled with oil to the correct level.
When checking the oil level in the bevel gear
- Check the oil level in the bevel gear.
Installing limiter and vibration damper
Install:
- the limiter
- the vibration damper.
Installing the propeller shaft on the bevel gear
- Install the propeller shaft. See to the bevel gear flange.
- Use new screws.
- 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 modified according to the Tool Bulletin.
Installing the drive shaft
Note! Before installing the bevel gear, lubricate the spline joint between the transmission and the bevel gear using grease.
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
- Apply metal adhesive, P/N 1161370-0, to the drive shaft splines. See the illustration.
- 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 nut by hand. Use a new nut. Lubricate the nut.
- 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 drive shaft nut
- Tighten the drive shaft nut
- Use counterhold 999 5540 and angle gauge 951 2050 .
- Tighten to 120 Nm + 60� angle.
- Remove the counterhold.
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.