Pinion Seal Bevel Gear, Replacing

Replacing the pinion seal for the bevel gear

Special tools:
999 5743 Counterhold 999 5743 Counterhold
999 5759 Adapter flange All-wheel drive 999 5759 Adapter Flange All-Wheel Drive
999 5069 EXTRACTOR 999 5069 Extractor
999 5504 PRESS TOOL, DRIVE FLANGE 999 5504 Press Tool, Drive Flange
999 5652 Counterh. 999 5652 Counterh.
999 5653 Punch 999 5653 Punch
999 5682 Tensioner band 999 5682 Tensioner Band
999 5893 Puller 999 5893 Puller

Note! Check that the parking brake is not applied or that a gear/position P is engaged.

Removal

Removing the three-way catalytic converter (TWC)
Remove the three-way catalytic converter (TWC) according to Replacing the three-way catalytic converter (TWC) Service and Repair.

Note! The rear pipe must be supported at the front.Tensioner band 999 5682 Tensioner band 999 5682 Tensioner Band 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 5743 Counterhold 999 5743 Counterhold.

Removing the propeller shaft




Slacken off the support for the centre 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 Counterh. 999 5652 Counterh. with adapter 999 5759 Adapter flange All-wheel drive 999 5759 Adapter Flange All-Wheel Drive.

Removing flange




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

Removing seal




Remove the seal.
Use puller 999 5069 EXTRACTOR 999 5069 Extractor.

Note! Carefully check that no seal residue is left.

Installation

Installing the seal




Install the seal.
Lubricate the sealing ring lip. Use wheel bearing grease, P/N 1161241-3. Install the seal on drift 999 5653 Punch 999 5653 Punch against the side of the tool marked 1155.
Press in the seal.
Use press tool 999 5504 PRESS TOOL, DRIVE FLANGE 999 5504 Press Tool, Drive Flange.

Installing the flange on the pinion




Install the flange as marked, see Removing the nuts for the bevel gear flange.
If necessary, use press tool 999 5504 PRESS TOOL, DRIVE FLANGE 999 5504 Press Tool, Drive Flange.

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 Counterh. 999 5652 Counterh. with adapter 999 5759 Adapter flange All-wheel drive 999 5759 Adapter Flange All-Wheel Drive.

Note! Do not exceed a tightening torque of 200Nm. 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 centre 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 5743 Counterhold 999 5743 Counterhold.
Tighten the screws for the support for the centre bearing to 25 Nm.
Tighten the screws for the propeller shaft centre bearing to 25 Nm.

Installing the three-way catalytic converter (TWC)
Install the three-way catalytic converter (TWC) according to Replacing the three-way catalytic converter (TWC) Service and Repair.

Checking the oil level in the bevel gear




Check the oil level in the bevel gear
Use the right oil. See applicable specifications.
Correct volume 650 ml.
Fill with oil up to the filling plug. Draw out 0.1 l oil.
Tighten the filling plug. See the relevant specifications.