Bevel Gear, Replacing
Bevel gear, replacing
Special tools: 998 5972, 999 5562, 999 7057, 999 7076
Note: As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.
Removal
Preparations
Note: Check that the parking brake is not applied and that the gear selector is in position P.
Disconnecting the front suspension components
Raise the car.
Remove
- the right front wheel
- the screw for the drive shaft and wheel hub
- the link for the anti-roll bar in the spring strut.
Removing front end components, continued
Remove
- the nut for the ball joint/link arm. Counterhold the ball joint pinion with a Torx wrench so that the boot does not twist
Note: Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
- the splashguard under the engine.
Removing the control arm from the ball joint
Lightly apply mobile jack 998 5972 under the right-hand side of the sub-frame.
Remove the screws from the support bracket for the sub-frame on the right-hand side
Slacken off the screws for the sub-frame.
Ensure that they are still secured by at least five turns of the thread. Remove the jack.
Unhook the control arm from the ball joint. Use jimmy tool 999 7076. Install protective sleeve 999 5562. Hold the sleeve in place using the nut for the ball joint.
Removing the drive shaft
Press out the wheel spindle. Detach the drive shaft from the hub. Do not damage the drive shaft boot. Use a tensioner band to pull the spring strut backwards.
Remove the screws from the bearing cap for the drive shaft. Pull the drive shaft straight out.
Note: Do not pull the outer part of the shaft. Doing so could damage the axial stops in the joints.
Removing the propeller shaft
Remove the front member from the body, exhaust pipe and Three-Way Catalytic Converter (TWC). Remove the brake pipe from the mountings in the member.
Remove the screws from the propeller shaft center bearing.
Slacken off screws from the support for the center bearing.
Marking the propeller shaft and flange
Mark up and remove the front propeller shaft CV joint from the bevel gear.
Press the drive shaft joints together as much as possible.
Remove the screws on left-hand side from the support for the center bearing.
Remove the shaft from the bevel gear.
Leave the end of the shaft resting against the anti-roll bar.
Note: Be careful. Do not damage the Heated Oxygen Sensor (HO2S) or its cable.
Removing bevel gear
Remove the 5 screws for the bevel gear. Pull the bevel gear straight out. Then turn it during removal.
Installation
Note: For tightening torques, see Specifications.
Note: Before installing the bevel gear, lubricate the spline joint between the transmission and the bevel gear. Use grease.
Installing the bevel gear
Ensure that the mating surfaces on the transmission and bevel gear are clean.
Install the bevel gear. Lightly tighten the M10 screws alternately. Tighten.
Installing the 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
Check carefully that the mating surfaces on the propeller shaft and flange are clean.
Use new screws.
Tighten the screws.
Installing members
Install the front member on the bodywork, exhaust pipe and Three-Way Catalytic Converter (TWC). Press the brake pipe into place in the mountings on the member.
Tighten
- the 4 x M8 screws for the front member
- the 4 x M8 screws for the support for the center bearing
- the 2 x M8 screws for the propeller shaft center bearing.
Installing the drive shaft and bearing cap on the pilot bearing for the shaft
Tighten the M8 screws.
Installing the drive shaft
Note: Check that the seal on the end of the drive shaft is correctly positioned.
Press out the spring strut. Align the drive shaft in the hub.
Locate the control arm on the ball joint pinion.
Apply mobile jack 998 5972 under the right-hand side of the sub-frame.
Press the frame up against the car body.
Replace the 2 x M14 screws. Lubricate the threads.
Install the screws for the support plate loosely.
Tighten the frame screws. Tighten the M10 screws for the support plate.
Checking the oil level in the bevel gear
Check the oil level in the bevel gear.
Installing front suspension components
Install
- the M12 nut for the ball joint and control arm.
Tighten. Counterhold using a Torx wrench so that the ball joint boot does not rotate
- the splash guard under the engine.
Installing front end components, continued
Install
- the screw for the drive shaft/wheel hub. Use a new screw. Tighten.
- the anti-roll bar link on the spring strut. Use a new M12 lock nut. Tighten
- the wheel.