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Home >> Volvo >> 2002 >> S60 Base, 2.4 61, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Transmission - Removal, Replacement And Installation - 1 Of 2 >> Auxiliary Transmission, Bevel Gear And Overdrive (B5254T4, TF-80SC AWD; 2006-2007) >> Bevel gear >> Sealing rings connecting socket, replacing >> Removal

Sealing rings connecting socket, replacing: Removal

Removing bevel gear 

Remove the bevel gear according to: Bevel gear replacing .

Fig 1: Identifying Removal Of Circlip From Connecting Socket
GLL109587Courtesy of VOLVO CARS OF NORTH AMERICA.

Carry out corrective action at worn splines in the sleeve 

Fig 2: Identifying Pressing Cardboard Disc Against The Seal
GLL161219Courtesy of VOLVO CARS OF NORTH AMERICA.

Cut out a Ø40 mm cardboard disc and use it to prevent metal shavings from entering the gearbox. Apply a thick bead of grease or petroleum jelly on the seal in the sleeve. Press the cardboard disc against the seal.

Fig 3: Identifying Grinding A Groove Inside Of The Sleeve
GLL161221Courtesy of VOLVO CARS OF NORTH AMERICA.

Grind a groove in the inside of the sleeve to 9995777 secure the expander.

The sleeve can also be heated using a hot air gun or induction heater.

Fig 4: Identifying Expander 999 5777, Puller Rod 999 5777 And Extractor 999 5777
GLL109588Courtesy of VOLVO CARS OF NORTH AMERICA.

Install: 9995777 and 9995777 to 9995575 .

9995575 used with: 9995576 (foot operated).

Alternatively: 9992615 , which consists of puller cylinder and a compressed air powered hydraulic pump.

Fig 5: Identifying Sleeve 999 5777 Positioned Between Puller Cylinder And Transmission
GLL109589Courtesy of VOLVO CARS OF NORTH AMERICA.
NOTE:

Place a container under the transmission.

Fig 6: Identifying Extracting Seal Using Special Tools, 999 7182 And 999 5069
GLL150222Courtesy of VOLVO CARS OF NORTH AMERICA.
Fig 7: Identifying Tapping Sealing Ring Out Of Socket Using Screwdriver
GLL109591Courtesy of VOLVO CARS OF NORTH AMERICA.