Bevel Box

Special tools and workshop equipment required

Engine Support Device 3300 A
Socket and Extended Bit T10107

Removing

Fig 1: Identifying Bolts -Arrows- And Air Guide

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-- Remove the air filter housing. Refer to Removal and Installation .

-- Remove the bolts -arrows- and remove air guide.

-- Remove the noise insulation -1-. Refer to "Underbody Trim Panels and Heat Shields" in Removal and Installation .

Fig 2: Removing Noise Insulation

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-- Remove the left and right front wheel spoilers. Refer to Removal and Installation .

Fig 3: Identifying Noise Insulation Frame

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-- Remove the right front wheel. Refer to Removal and Installation .

Fig 4: Identifying Right Driveshaft Heat Shield And Bevel Box

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-- Remove the right drive axle heat shield from bevel box -arrows-.

-- Remove right drive axle from transmission flange.

-- Lift up right drive axle and secure with cable tie.

NOTE:

Be careful not to damage the protective coating on the drive axle.

-- Disconnect the connector -1- on the oil level thermal sensor -G266-.

Fig 5: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

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-- Remove the bracket -2- for the oil level thermal sensor wire from the subframe.

-- Remove the bolts -1 and 2- and the bevel box mount -A-.

Fig 6: Bevel Box Bracket & Bolts

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-- Identify position of flexible disc and bevel box flange to each other.

Fig 7: Driveshaft Flexible Disc

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-- Remove driveshaft flexible disc from bevel box -arrows- while counter holding at triangular flange with a lever.

Fig 8: Identifying Driveshaft Flange Shaft Seal

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CAUTION:

Risk of damaging sealing ring -arrow - in driveshaft flange.

Press driveshaft horizontally as far back and to the right side of the vehicle as possible.

-- Remove the bolts -2 and 3- from the pendulum support.

Fig 9: Identifying Pendulum Support & Bolts

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-- Press engine/transmission assembly forward slightly and remove driveshaft from bevel box.

NOTE:

Ignore -1-.

-- Remove right flange shaft bolt with T10107 by installing 2 bolts in the flange and counter holding flange shaft with assembly lever.

Fig 10: Identifying Right Flange Shaft Countersunk Bolt, Socket And Key T10107

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-- Remove the bevel box bolts -arrows- on the transmission.

Fig 11: Identifying Bevel Box Bolts -Arrows-

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-- Tighten 3300 A on the subframe.

Fig 12: Tighten 3300 A On Subframe

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-- Place 3300 A spindle on oil pan with rubber piece inserted between -1-.

-- Press engine forward by dimension -a- using 3300 A spindle.

-a- = 160 mm

-- Remove bevel box from transmission together with right flange shaft.

-- Turn bevel box and guide out between engine oil pan and subframe as shown in illustration.

Fig 13: Turning Bevel Box And Guide Out Between Engine Oil Pan

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Installing

Install in reverse order, paying attention to the following:

For the correct tightening specifications, refer to FLANGE SHAFT, SEALS AND BRACKET ON BEVEL BOX OVERVIEW .

CAUTION:

Risk of damaging sealing ring between transmission and bevel box.

Place the bevel box on the transmission together with right flange shaft while turning shaft.

-- Tighten bevel box on transmission.

-- Install the right flange shaft. Refer to RIGHT FLANGE SHAFT .

-- Install bevel box bracket. Refer to Fig 14.

Fig 14: Bevel Box Bracket & Bolts

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Fig 15: Bevel Box Bracket & Bolts

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Fig 16: Identifying Driveshaft Flange Shaft Seal

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CAUTION:

Risk of damaging sealing ring -arrow - in driveshaft flange.

Press engine/transmission assembly toward bulkhead while carefully guiding bevel box pins into driveshaft flange.

-- Slide the driveshaft horizontally onto the guide pins. Refer to Final Drive, Differential .

-- Tighten the pendulum support on transmission. Refer to PENDULUM SUPPORT .

Fig 17: Identifying Pendulum Support & Bolts

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During removal, pay attention to the markings on the driveshaft and flange. These must be aligned with each other -arrows-.

Fig 18: Aligning Markings On Driveshaft At Flange Of Haldex Clutch

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-- Counter hold the triangular flange with a lever and tighten the driveshaft with the flexible disc to the flange on the bevel box -arrows-. Refer to Removal and Installation .

Fig 19: Driveshaft Flexible Disc

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-- Install the right drive axle. Refer to Removal and Installation .

-- Axle oil level, checking and filling. Refer to AXLE OIL LEVEL, CHECKING AND FILLING .