Bevel Box, Installing
"Bevel Box, Removing". Refer to BEVEL BOX, REMOVING to get a list of the special tools needed.
Replace self-locking bolts and nuts after removing them.
Replace the bolts that were tightened with an additional turn after removing them.
Reinstall all cable ties that were loosened or cut off during removal at the same locations during installation.
Install in the reverse order of removal while noting the following:
-- Coat the splines on the manual transmission differential with Grease for Clutch Plate Shaft Splines.
-- Secure the Engine Support: T50015 to the subframe using the M8 x 25 collar bolt -A-.
-- Secure the Holding Fixture - Gearbox Adapter: T10235 for attaching the Engine Support: T50015A in the rear threaded hole for the pendulum support on the transmission.
-B- = washer approximately 2 mm thick.
-- Push the engine/transmission forward while paying attention to the stop on the radiator.
-- Slide the bevel box as far as possible onto the manual transmission. While doing so, join the splines of input shaft/bevel box centrally with the differential.
-- With the proper tooth position and central guiding, the bevel box slides against the manual transmission.
The space to access the upper bevel box bolts on the manual transmission is narrow.
Layout of the upper bevel box bolts (-1- and -2-) on the manual transmission (covered by the bevel box).
- The bolt -1- is located near the bolt -A-.
- The bolt -2- is located near the bolt with the threaded connection -B-.
- The front exhaust pipe with the catalytic converter or the particulate filter -C- is located above the bolts.
Do not tighten the bevel box against the transmission with the bolts, otherwise the bevel box could tilt and the eyes could break off.
-- Tighten the upper and lower bevel box bolts -arrows- on the transmission using a commercially available socket. Refer to OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK .
The bevel box upper bolts -arrow a- and -arrow b- to the manual transmission -1- are accessible from the engine compartment.
-- If removed, install the EGR cooler. Refer to the appropriate Service Information .
-- Fasten the flange shaft with a new bolt. Refer to OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK .
-- Secure the bevel box transmission support to the engine and bevel box while pay attention to the tightening sequence for the bolts -1- and -2-. Refer to Figure.
-- Install the Engine Support: T50015 .
-- Install the pendulum support with new bolts. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .
Threaded inserts (for example, "Heli Coil") are found in the pendulum support fastening holes on some transmissions. Refer to Figure.
-- When installing the pendulum support, position the driveshaft with the flexible disc on the bevel box flange.
-- When positioning, make sure that the seal -arrow- in the centering bushing is not damaged.
-- Attach the driveshaft to the bevel box flange -arrows-. Refer to the appropriate Service Information .
-- Attach the heat shield -1-. Refer to the appropriate Service Information .
-- Assemble the exhaust system. Refer to OVERVIEW - MUFFLER .
-- Install the right drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .
-- Check the transmission fluid level in the manual transmission. Refer to TRANSMISSION FLUID LEVEL, CHECKING .
-- If equipped, install the drive axle heat shield on the bevel box -arrows-. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .
The right drive axle heat shield is attached with two or three nuts.
-- Install the Heater Support Pump -V488-. Refer to OVERVIEW - ELECTRIC COOLANT PUMP .
-- Connect the connector -1- to the Oil Level Thermal Sensor -G266-.
-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .
Tightening Specifications
- Refer to OVERVIEW - BEVEL BOX