Pinion Seal Bevel Gear, Replacing

Replacing bevel gear pinion seal
Special tools: 999 5743B, 999 5759, 999 5069, 999 5504, 999 5652, 999 5653, 999 5682, 999 5893

Note: Check that the parking brake is not applied and that the gear selector is in position P.

Removal
Removing the three-way catalytic converter (TWC)
Remove the Three-Way Catalytic Converter (TWC).

Note: The rear pipe must be supported at the front.
Tensioner band 999 5682 can be used to support the pipe.

Marking the propeller shaft and flange Mark the propeller shaft CV joint in relation to the bevel gear flange





Remove the screws from the propeller shaft.
Use counterhold 999 5743B.

Removing the propeller shaft





Slacken off the support for the center bearing from the propeller shaft and body. Turn the support upside down. Let the propeller shaft rest on the support.
Press the shaft nuts together. Move the shaft to one side and tie it up.

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 with adapter 999 5759.

Removing flange





Remove the flange. Use puller 999 5893.
Check the seal face on the flange.
Replace the carrier plate if it is damaged.

Removing seal





Remove the seal.
Use puller 999 5069.

Note: Check that no seal residue is left.

Installation
Installing the seal





Install the seal.
Lubricate the sealing ring lip with 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 the flange on the pinion
Install the flange as marked.





If necessary, use tool 999 5504.

Installing a new nut for the flange
Install a new lubricated nut.

Note: There must be no axial play.

Tighten to 180-200 Nm. Use counterhold 999 5652 with adapter 999 5759.

Note: Do not exceed a tightening torque of 200 Nm. The forces on the pinion bearing may become too great, causing it to seize.

Installing propeller shaft





Check that the mating surfaces on the propeller shaft CV joint and flange are clean.
Align the propeller shaft CV joint against the flange.
Install the screws loosely in the support for the center bearing and the propeller shaft.





Install the propeller shaft using the marking made earlier.

Tightening the propeller shaft CV joint
Use new screws.
First tighten the screws crosswise to 8 Nm.
Then tighten to 30 Nm.
Use counterhold 999 5743B.
Tighten the screws for the support for the center bearing to 25 Nm.
Tighten the screws for the propeller shaft center bearing to 25 Nm.

Installing the Three-Way Catalytic Converter (TWC)
Install the Three-Way Catalytic Converter (TWC).

Checking the oil level in the bevel gear





Only use transmission fluid. P/N: 1161513-5
Correct volume: 750 ml.
Tighten the level plug to 35 Nm.