Bevel Gear, Replacing, AW42 AWD
Removing bevel gear
Special tools:
951 2050
999 5006
999 5460
999 5540
999 5561
999 5562
999 5563
Note! Carefully follow the instructions how to place the lifting arms. Towing, changing wheels and rolling road / wheel spinner test.
Preparations
Installing the lifting device
Install:
- lifting brace 999 5006 . Place the brace directly above the lifting hole on the engine's torque arm
- lifting hook 999 5460 in the torque arm. Pull on the hook slightly
Block the steering servo line's return hose with a hose clamp
Removing the front wheels
On the right-hand side. Remove:
- the screw to the brake hose bracket. Unhook the bracket
- ABS-sensor. Suspend the sensor from a wire
Note! Do not disconnect the connector.
- the nut on the drive shaft, use a counterhold 999 5540 . Knock the end of the drive shaft 10-15 mm into the hub. Use a copper or plastic hammer.
Removing the link and ball-joint
On both sides:
Remove the nut on the anti-roll bar link and unhook the link from the anti-roll bar.
On the right-hand side:
Remove the screw on the wheel spindle - balljoint. Loosen the ball-joint from the wheel spindle. Fit a protective sleeve 999 5562 on the
ball-joint.
On the right-hand side: Installation of the retainer for the control arm
- Install the retainer 999 5563 to hold down the control arm.
- Push the drive shaft in to its inner position.
- Turn and fold out the spring strut.
- Remove the drive shaft from the hub.
Removing the right drive shaft
Remove:
- the bearing cap for the drive shaft
- drive shaft. Carefully pull it out from the transmission so that the sealing ring is not damaged.
Loosen the servo oil pipe from the steering gear
Remove the vibration damper.
Remove the collision protection system over the steering gear
Remove the oil pipes' brackets from:
- the collision protection system.
- the sub-frame
- the bracket holding the pipes on the front edge.
Position a container under the steering gear to collect the oil.
Loosen the oil pipes from the steering gear.
Move the pipes to the side and tie them up.
Seal the openings in the steering gear using plastic plugs. Also protect the pipes from contamination.
Only cars with the steering column in a late design (S70/V70)
Note! On cars with steering columns in a later design: Adjust the steering shaft so that the screws/nuts for the outer and inner joints can be easily accessed. Now remove the ignition key so that the steering is locked in this position. Loosen the joint from the lower steering shaft inside the car.
Removal of the steering shaft joint and the bevel gear's limiter.
Remove the bevel gears limiter
Early design: Adjust the steering shaft so that the screws/nuts for the outer and inner joints can be easily accessed.
Now remove the ignition key so that the steering position is locked.
Early and late designs: Remove the screw for the steering shaft joint. Slide up the joint from the steering shaft.
On late designs (S70/V70): Remove the joint/lower steering shaft
Note! The position of the steering shaft must not now be moved, that is to say, so that the pinion turns one revolution . If the position of the steering shaft changes, the SRSsystem's contact reel can be destroyed.
Lower the rear edge of the sub-frame
Unhook the fuel pipes from the bracket on the sub-frame
Remove the screws on the left-hand engine mounting from the sub-frame
Apply the transmission jack lightly on the subframe.
Remove the screws for the sub-frame's rear edge mountings on both sides.
Lower the sub-frame so that it hangs free.
Marking the flange
Mark the propeller shaft's flange in relation to the bevel gear's flange
Note! Mark up only if reinstalling the bevel gear.
Remove the screws from the propeller shaft Use a counterhold 999 5561. Change according to the tool bulletin.
Removing bevel gear
Remove the exhaust pipe bracket
Remove the remaining screws holding the bevel gear. Lift off the bevel gear
Check
Check that the connecting sleeve between the transmission and bevel gear is seated correctly and that there is no oil leakage.
Installing the bevel gear
Note! Before installing the angle gear the splined joint between the gearbox and the angle gear must be lubricated with grease in accordance with: Splines infettning .
Check that there is no oil leakage between the bevel gear's connecting sleeve and the sealing ring on the transmission, and that the sleeve is not generally damaged and is seated correctly.
Make sure that the contact faces on the transmission and bevel gear are clean.
Install new screws.
Do not forget the exhaust pipe bracket. Lightly tighten the screws. Then tighten to 75 Nm.
Installing the propeller shaft for the bevel gear
Install the propeller shaft according to:
Marking the flange on the bevel gear flange .
Note! If the bevel gear, flange, etc has been replaced: Install the propeller shaft in any position.
Make sure that the contact faces on the propeller shaft and flange are clean.
Note! Use new screws when installing the propeller shaft.
Tighten the screws crosswise with 8 Nm , then tighten with 30 Nm . Start with the same screw on both occasions.
Use a counterhold 999 5561 . Change according to the tool bulletin.
Lifting sub-frame
Lift up the sub-frame by the rear edge
Use the mobile jack.
Note! On early designs: Exercise care so that the steering shaft joint does not become jammed.
Note! Use new screws (M14) on the subframe. Lubricate the screw threads.
Fit the screws for the sub-frame and support bracket. First tighten the sub-frame screws to 105 Nm + 120° and then the screws for the sub-frame�s bracket with 50 Nm . Use an angle gauge 951 2050.
Tighten the screws for the left-hand engine mounting with 50 Nm.
Hook the fuel pipes on the bracket on the subframe.
Installing the steering wheel shaft joint
Late design: Check that the bearing in the boot for the lower steering shaft is seated
Early and late designs: Align and slide on the steering axle joint on the steering shaft pinion
Fit the screws for the steering shaft joint and steering gear.
Slide the steering shaft joint up towards the boot before tightening. Use a new lock nut. Tighten the nut with 20 Nm. Install the lock eye bolt.
Install the limiter. Tighten with 50 Nm.
Installation of the joint, late design (S70/V70)
Install the joint for the lower steering shaft inside the car
Use a new wing screw and new flange lock nut. Tighten with 30 Nm.
Installation of pipes and collision protection system
Install:
- servo oil pipes for the steering gear. Use new O-rings
- the pipes' mounting on the sub-frame
- the collision protection system.
- the pipes' retaining clips.
First assemble all parts loosely. Then tighten the oil pipes first and then the brackets.
Install:
- the collision protection system over the steering gear. Tighten with 80 Nm
- the vibration damper. Tighten to 25 Nm.
Installing the drive shaft
Installation of the drive shaft for the transmission/angle gear and pilot bearing bracket
Install the drive shaft for pilot bearing bracket
Tighten the screws for the bearing cap with 25 Nm.
Installation of the drive shaft for the hub
Install the drive shaft for the hub
- Apply metal adhesive, part number 1161370-0, on the splines on the drive shaft.
- See the inset figure in the top, right corner.
- Fold out and turn the spring strut.
- Align the drive shaft in the hub.
- Fit the drive shaft nut by hand.
- Use a new nut. Lubricate the nut.
- Remove the retainer.
Note! Take care not to damage the drive shaft boot.
Installation of the control arm/ball joint
- Install the control arm/ball-joint for wheel spindle
- Remove the sleeve 999 5562 from the ball-joint.
- Make sure that the ball-joint stud fits in the screw hole in the wheel spindle.
- Use new lock nuts. Tighten with 50 Nm .
- Install the link for the anti-roll bar on both sides.
- Use new lock nuts. Tighten with 50 Nm .
Tightening the drive shaft nuts
- Tightening of the drive shaft nuts
- Use a counterhold 999 5540 and angle gauge 951 2050 . Tighten with 120 Nm + 60° angle.
- Remove the counterhold.
Installation of the bracket and ABS sensor
- Installation of the bracket for the bake pipe /ABS cable
- Clean the ABS sensor with a soft brush.
- Lubricate the sensors hole with wheel bearing grease, part number 1161241-3.
- Install the ABS sensor for the wheel spindle
Note! Check that the ABS sensor seating is absolutely clean.
- Tighten the sensor with 10 Nm.
- Install the wheel. Tightening the wheel studs.
Removing lifting hook and lifting brace
Remove:
- lifting hook
- lifting brace
- hose clip.
Bleeding the hydraulic system
- Fill the servo tank with oil and bleed the system
- Hydraulic oil, type ATF-oil F, G, Dexron II D, E, III, Ford Mercon. Alternative: Volvo servo oil (for cold climates), part number 1161317-1 (1 liter).
- Turn the steering wheel between both end positions repeatedly. Fill with oil if necessary.
- Unblock the car.
- Apply the parking brake.
- Start the engine.
- Check the oil level when bleeding the system:
- A. Turn the steering wheel slowly to the right, keep it at the end position for 10 seconds.
- B. Turn the steering wheel slowly to the left, keep it at the end position for 10 seconds.
- Repeat steps A and B 20 times.
- Move the car after 10 times to prevent damage to the tires.