Bevel Box, Installing, Vehicles With 3.6L, 206 Kw Engine

Special tools and workshop equipment required

Grease for Clutch Plate Shaft Splines: G 000 100

Install in reverse order of removal while noting the following:

-- Grease the splines on the differential with Grease for Clutch Plate Shaft Splines: G 000 100 .

Fig 1: Identifying Circlip -A- And O-Ring -B-

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-- Install the new circlip -arrow A- and the new O-ring -arrow B- on the right stub shaft.

-- Insert the bevel box and press it against the transmission as far as the stop.

NOTE:

If the tooth position is incorrect (the bevel box cannot be pressed against the transmission), rotate at the stub shaft.

-- If the tooth position is correct and it is guided centered, the bevel box slides against the transmission all the way.

CAUTION:

Hit the stub shaft locking ring onto the toothed lug with a plastic hammer on the front side to make sure it is engaged correctly into the differential bevel gear. Do not pull the bevel box forcefully against the transmission by rotating the bolts. The transmission or bevel box could be damaged.

-- First tighten the bevel box with the new bolts -arrows- by hand and then finish tightening. Tightening specification. Refer to TRANSMISSION AND BEVEL BOX TIGHTENING SPECIFICATIONS .

Fig 2: Identifying Bevel Box Bolts

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-- Install the bevel box transmission support. Pay attention to the component location and tightening sequence for the bolts. Refer to TRANSMISSION SUPPORT TO ENGINE AND BEVEL BOX .

Fig 3: Vehicles with 3.6L - 206 kW Engine

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-- Attach the drive axle heat shield -1- if equipped on the bevel box (-arrows-). Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

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-- Install the driveshaft on the bevel box.

NOTE:

Seal in driveshaft flange -arrow- must not be damaged when removing and installing the bevel box. Replace the driveshaft if it is damaged.

Fig 4: Identifying Driveshaft Flange Shaft Seal

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-- Install the driveshaft on the bevel box -arrows-. Refer to the appropriate Service Information .

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-- Install the driveshaft heat shield -1-, if equipped.

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-- Install the right drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the exhaust system section. Refer to OVERVIEW - MUFFLER [CDVC] or OVERVIEW - MUFFLER [DCGA, CXDA] .

Further installation is performed in reverse order of the removal.

-- Check the gear oil level in bevel box. Refer to GEAR OIL, CHECKING LEVEL .

-- After installation check the oil level in the transmission. Refer to ATF LEVEL, CHECKING .

-- Install the noise insulation. Refer to Noise Insulation .

Tightening Specifications. Refer to Figure.