Replacing the Bevel Gear/Chain Housing
Replacing the bevel gear/chain housing
Special tools:
999 5462 Jimmy tool 999 5462 Jimmy Tool
999 7057 Counterhold 999 7057 Counterhold
999 7063 Drift 999 7063 Drift
Note! Since 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
Drain the gearbox fluid.
Use an oil suction device to drain approximately 4 liters of gearbox fluid.
Remove the sub-frame. See: Sub-frame front, replacing Service and Repair.
Removing the right drive shaft
Angle the wheel hub out. Remove the drive shaft from the hub. Use a tensioner band to pull the stub axle - wheel hub backwards.
Remove the drive shaft from the gearbox. Use Jimmy bar 999 5462 Jimmy tool 999 5462 Jimmy Tool B (modified according to the Workshop Guide Bulletin).
Install sealing plug 999 7063 Drift 999 7063 Drift.
Pay attention to the following when removing propeller shaft
Follow instructions. Refer to: Propeller shaft, special information Description and Operation
Removing the propeller shaft
Mark the propeller shaft CV joint in relation to the bevel gear flange.
Remove:
- the 2 screws for the centre bearing mounting
- the propeller shaft screws. Use counterhold 999 7057 Counterhold 999 7057 Counterhold. Press the propeller shaft joints together. Move the propeller shaft to one side and tie it up.
Disconnecting the steering gear from the engine pad
Mark up the position of the steering gear in relation to the engine pad.
Remove the screw for the steering gear and engine pad.
Move the steering gear towards the bulkhead. Hold it up using tie straps.
Removing the chain housing bracket
Remove:
- the screw in the clamp for the fuel line
- the bracket for the chain housing/engine.
Removing the bevel gear/chain housing
Remove:
- the screw for the bevel gear/engine. The screw is positioned on top of the bevel gear. The screw can be accessed from the centre
- the screw between the chain housing/bracket and the other screws in the bracket.
Pull the chain housing/bevel gear 5-10 mm out from the gearbox. Then remove the bracket. The bracket is upturned with a guide sleeve in the gearbox end.
Note! Two people are required to carry out the following procedure as the bevel gear - chain housing is relatively large.
Remove the bevel gear/chain housing by first pulling it straight out from the gearbox.
Note! Do not damage the seal ring in the transmission end.
Then turn the unit so that it can be removed to the side and downwards.
Checking the sealing ring
Check that the sealing ring in the gearbox end is undamaged.
Replace the sealing ring with a new sealing ring if damaged, see Seal, drive shaft, replacing Seal, Drive Shaft, Replacing and /or Seal, drive shaft, replacing Seal, Drive Shaft, Replacing.
Separating the bevel gear/chain housing
Remove the 4 screws. Pull the chain housing straight out from the bevel gear.
Note! Do not place the chain housing with the opening for the bevel gear facing down, oil will run out.
Checking the chain housing
Check that the sealing rings and mating surfaces are not damaged. Check for leakage. Replace the chain housing in the event of leakage.
Hint: A new chain housing is not filled with oil.
Checking the bevel gear
Check that the sealing rings and mating surfaces are not damaged. Check for leakage. Replace the bevel gear in the event of leakage or damage.
Hint: A new bevel gear is filled with oil, however, always check the oil level before test driving.
Installation
Note! For tightening torques, see Tightening Torque
Assembling the bevel gear/chain housing
Lubricate the seal using gearbox fluid, P/N 116 1745-3 (1 liter container) when replacing the chain housing.
Do not damage the sealing ring when installing the chain housing on the bevel gear.
Install the 4x M10 screws. Tighten crosswise lightly. Then tighten the screws.
Installing the bevel gear/chain housing
Note! Two people are required to carry out the following procedure as the bevel gear/chain housing is relatively large.
Note! Make sure that the chain housing's shaft journal does not damage the seal in the transmission end.
Lift up the unit and align the shaft journal in the gearbox. Do not press the unit end in.
Install the bracket and guide sleeve in the gearbox. Press in the unit.
Install all 4x M10 screws loosely. Tighten crosswise lightly. Then tighten the screws.
Installing the bracket
Install the bracket on the cylinder block and chain housing using 6x M10 screws.
First tighten the screws for the bracket/cylinder block so that the bracket can moves slightly.
Then tighten the two screws to the bracket - chain housing alternately lightly.
Then tighten all the screws.
Install the screws for the fuel line clamp. Tighten.
Installing the propeller shaft
Install the propeller shaft using the marking made earlier.
Check carefully that the mating surfaces on the propeller shaft and flange are clean. Install the 6x M8 screws and washers. Tighten. See Propeller Shaft, Replacing Use counterhold 999 7057 Counterhold 999 7057 Counterhold.
Install the 2x M8 screws to the propeller shaft center bearing. Tighten.
Installing the steering gear to the engine pad
Install the 1 M10 screw for the steering gear and engine pad. Align the steering gear in relation to the engine pad, using the marking made earlier. Tighten.
Installing the right drive shaft
Lubricate the seal using gearbox fluid, P/N 116 1745-3 (1 liter container) if the chain housing or its sealing ring has been replaced.
Press the drive shaft into the gearbox. Check that the snap ring is in its groove by carefully pulling it in the inner constant velocity joint.
Locate the drive shaft in the wheel hub.
Filling and checking oil
Fill and check the oil in:
- bevel gear. Use the right oil. See: Specifications
Correct volume 650 ml.
Fill with oil up to the filling plug. Draw out 0.1 l oil.
Tighten the filling plug.
- chain housing. Only use oil with P/N 116 1745-3 (1 liter). Tighten according to Tightening Torque
Finishing
Install the sub-frame. See Sub-frame front, replacing Service and Repair.
Fill the gearbox with exactly the same amount of new oil as was drained off. Only use automatic gearbox fluid, P/N 116 1521 (1 liter container) or 116 1621 (4 liter container).
Check the gearbox oil. See Oil level, checking Checking Oil Level.