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Dismantling and assembling bevel box > < Servicing bevel box

A3 Mk1

Bevel box - exploded view
Bevel box - exploded view
  Note
t  There are two different bevel box types fitted: bevel boxes with output shaft → Item and drive flange → Item or bevel boxes with flange shaft → Item. These components must not be interchanged. Allocate to the corresponding type of bevel box when renewing.
t  Adjust bevel gear or shaft bevel gear (final drive gear set) when renewing tapered roller bearings, cover, output flange, final drive housing, bevel gear with input shaft, shaft bevel gear or the pinion housing → .
   
1 - Cap
q   Destroyed during removal
q   Renew
2 - Circlip
q   Renew
3 - Dished spring
q   Taper faces circlip
4 - Countersunk bolt, 25 Nm
5 - Flange shaft
6 - Needle bearing (polygon bearing)
q   2 x
q   Only for flange shaft → Item
q   Renewing → Chapter
7 - Drive flange
q   Pulling out → Anchor with output shaft → Item
q   Pressing off → Anchor
q   Pressing on → Anchor
8 - Output shaft
q   Pull out of bevel box housing → Anchor with drive flange → Item
9 - Needle bearing (polygon bearing)
q   Only for output shaft
q   Renewing → Chapter
10 - Circlip
q   Renew
11 - Oil seal
q   Renewing → Chapter
12 - Bolt, 25 Nm
13 - Cover
q   Removing → Anchor
q   Keep straight when installing, tighten securing bolts diagonally and in stages
14 - O-ring
q   Renew
q   Must be seated in circumferential groove
15 - Shim “S1”
q   Note thickness
q   Table of adjustments → Anchor
16 - Large tapered roller bearing for bevel gear
q   Pulling off inner race → Anchor
q   Pressing on inner race → Anchor
q   Pressing out outer race → Anchor
q   Pressing in outer race → Anchor
17 - Bevel gear with input shaft
q   Is paired with shaft bevel gear → Item
q   Cannot be pressed off input shaft
q   Adjusting → Chapter
18 - Small tapered roller bearing for bevel gear
q   Pressing off inner race → Anchor
q   Pressing on inner race → Anchor
q   Pressing out outer race → Anchor
q   Pressing in outer race → Anchor
19 - Shim “S2”
q   Note thickness
q   Table of adjustments → Anchor
20 - Final drive housing
21 - Oil seal
q   Renew
q   Insert stepped side into final drive housing
22 - O-ring
q   Renew
23 - Oil seal
q   Renew
q   Insert stepped side into final drive housing
24 - Oil drain plug, 25 Nm
q   With magnet
25 - Roller bearing
q   Pulling out → Anchor
q   Pressing in → Anchor
26 - Circlip
q   Renew
q   Removing → Anchor
27 - Shaft bevel gear
q   Is paired with bevel gear
q   Clean thread
q   Adjusting → Chapter
28 - Large tapered roller bearing for shaft bevel gear
q   Pulling off inner race → Anchor
q   Pressing on inner race → Anchor
q   Pulling out outer race → Anchor
q   Pressing in outer race → Anchor
29 - Output flange
30 - Hexagon nut, 350 Nm
q   Slackening → Anchor
q   Renew
q   Lubricate with gear oil before installing
q   Tightening sequence → Anchor
31 - Shim “S4”
q   Note thickness
q   Table of adjustments → Anchor
q   Fit onto spacer ring → Item before installing oil seal → Item and small tapered roller bearing inner race → Item
32 - Spacer ring
q   Installation position: chamfer faces shaft bevel gear → Item
q   Fit onto shaft bevel gear → Item before installing oil seal → Item, shim “S4” and small tapered roller bearing inner race → Item
33 - Oil seal
q   Renew only with bevel box removed → Chapter
q   Pinion housing → Item does not have to be detached
34 - Small tapered roller bearing for shaft bevel gear
q   Pressing out outer race → Anchor
q   Pressing in outer race → Anchor
q   Insert inner race in outer race
35 - Bolt, 25 Nm
36 - Pinion housing
q   Removing → Anchor
q   Installing → Anchor
q   Keep straight when installing, tighten securing bolts diagonally and in stages
37 - O-ring
q   Renew
q   Must rest in circumferential groove
38 - Shim “S3”
q   Note thickness
q   Table of adjustments → Anchor

   

Dismantling and assembling bevel box > < Servicing bevel box