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Removed Bevel Gear - comments on the job V70-XC70 1998

posted by  jadnhm on  Mon Sep 21 05:18 CST 2009
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last visit: Tue May 22 18:03 CST 2012
[RELATED]

This weekend I removed the bevel gear in my 1998 V70 AWD.

I mentioned that I might think about this some time ago when I started experiencing problems with it:
http://www.brickboard.com/AWD/volvo/1356332/V70/front_end_whine.html

As I mentioned in that posting, I came across this thread on VolvoXC about removing the bevel gear completely:
http://www.brickboard.com/AWD/volvo/1356332/V70/front_end_whine.html

At first I thought the volvoxc poster described replacing his pass side driveshaft with one from a FWD car, but as it turns out he actually just used the regular one from his AWD. The driveshaft on the AWD car actually passes all the way through the bevel gear and mates into the transmission directly. The bevel gear gets it's power from a small shaft that fits around the pass side driveshaft and splines into the bevel gear's power-transfer assembly.

I did all this because I had to replace the pass side ball joint. I had to take the ball joint out, so I was most of the way to getting the driveshaft out anyway, and I wanted to replace the outer boot (I bought the boots sometime ago, waiting for the right opportunity to get to it).

I pulled the control arm out and took the driveshaft out of the hub assembly, unbolted the carrier bearing and pulled the driveshaft out of the car. Easy.

Then I removed the vibration damper and drained the oil out of the bevel gear through the drain I installed some time ago.

Then I started unbolting the bevel gear. There are 5 bolts holding the bevel gear to the transmission, all 14mm. The two "on top" of the bevel gear housing were best reached with extensions from the pass side, over the top of the housing. It was helpful that I already removed the driveshaft.

The bevel gear itself then came out with only mild finangling.

When I looked this procedure up in VADIS it specified that I would need to put an engine lifting device on top of the strut towers and lower the sub-frame and undo the exhaust and all this... total balogney.

After that I just put it all together in reverse. I greased everything up good to keep the nasty moisture away from things - splines and driveshaft, trans seal, etc - anything that I didn't really want the water on).

I also used my old CV boot to make a boot to cover the interface between the driveshaft and the small shaft for the bevel gear (which stays put in the transmission after the bevel gear is removed). This was not hard at all and I greatly recommend this to anyone trying this for themselves. Basically I just found one of the 'valleys' in the 'bellows' part of the boot that was approx the same diameter as the small bevel gear shaft and trimmed the boot using a pair of scissors a little up the next bellow so that I could fasten the boot to the shaft using a zip-tie. The other end was already the right size for the driveshaft given that it came off the driveshaft to begin with :) It was easy. I tried to recycle an old inner tie-rod boot, but it wasn't big enough. CV boots work well. I'll get a picture of this if I can remember to think of it the next time I'm under there.

There was a small metal bracket supporting the exhaust that should probably be fastened by shimming out with washers (to replicate the depth of the bevel gear housing that is now gone.

Overall the job was not that bad, and now I'm a-bunch-of-pounds lighter (maybe 50? I'm really bad at judging weight...) and I have the bevel gear out so I can get it checked out and possibly rebuilt at a transmission shop.

So if you've got an AWD that you have already removed the prop shaft from (making it a FWD) and you're up to the task of removing the pass-side driveshaft, it's a short step to go the extra mile and remove the bevel gear altogether if you so choose.


--
1998 V70 AWD Turbo 195k+








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    Removed Bevel Gear - comments on the job V70-XC70 1998

    posted by  jadnhm on  Wed Sep 23 00:53 CST 2009
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    last visit: Tue May 22 18:03 CST 2012
    [RELATED]

    I discovered a problem with this setup today. The small shaft (that wraps around the pass side driveshaft that is meant to transfer power to the bevel gear) seems to require some pressure against whatever it seats against inside the transmission. Without seating tightly enough, transmission fluid leaks out of the transmission.

    Some good has come of it - I can tell I need to flush my trans fluid again from the colour and smell of the fluid...

    Anyway, I put some metal adhesive on the shaft and built a little retainer for the shaft out of a plastic spray paint can cover. It seems to work for now, but I might just end up putting the bevel gear back on sooner rather than later. I don't know how well this is going to last.

    As I stated in the first post, the intent of pulling it out was to give me time to get it checked out and look into the possibility of repair/rebuild. If I end up putting it back on I will just have to delay that.

    --
    1998 V70 AWD Turbo 195k+








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      Removed Bevel Gear - comments on the job V70-XC70 1998

      posted by  jadnhm on  Fri Sep 25 01:57 CST 2009
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      last visit: Tue May 22 18:03 CST 2012
      [RELATED]

      My leak has stopped!

      I am not sure how confident I feel about this lasting for the long haul, so I may pull it apart and lock it in place again, this time using the better red loctite. Still, for the time being my leak has stopped.

      Also, I'm getting some advice from a local transmission shop on rebuilding the bevel gear and it sounds like we might be looking at a pretty successful procedure for a decent price. I will be sure to update the board if it turns out that these thing are indeed rebuild-able if only you can find a persistent technician.
      --
      1998 V70 AWD Turbo 195k+








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      Removed Bevel Gear - comments on the job V70-XC70 1998

      posted by  will rehsper on  Wed Sep 23 03:32 CST 2009
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      last visit: Tue Jul 3 14:55 CST 2012
      [RELATED]

      Good that you made an actual retainer for that shaft. I cringe and recoil in horror at the thought of using only a Loctite thread locker be it purple, blue red or green) to keep anything in place. --Especially for something that moves, cycles in temperature and is exposed to oil.

      Red loctite can be good stuff when used correctly in the correct application, but it is never meant to be used as the volvoxc.com thread seems to suggest (to hold a shaft in the tranny). It's for keeping the retention feature in place and maintaining a preload, not to take the place of a screw or other bolted foundation.

      Thanks for sharing this information.

      -Will
      --
      854 - 244 - Mini








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        Removed Bevel Gear - comments on the job V70-XC70 1998

        posted by  jadnhm on  Wed Sep 23 05:23 CST 2009
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        last visit: Tue May 22 18:03 CST 2012
        [RELATED]

        Thanks for the comments Will. Esp your thoughts regarding the use of threadlocker in this case.

        I only had blue/medium threadlocker on hand at the time (blue seems to be good enough for most any purpose I have come up against) but I think I'm going to go pick up some of the stronger stuff and try to really stick it in there.

        I'm also trying to think of a way to make my plastic retainer better as well. That little shaft isn't going anywhere for sure, but it's not providing much in the way of 'pressure' either. It's on my mind anyway.

        There are two seals here - the one visible from the outside and flush with the trans housing, and then one on the inside of this. The inside one is the one that seems to be responsible for keeping the fluid in. The shaft must be pushed in to seat against this inside seal in order to properly make the seal.

        I'll keep everyone informed how this goes.

        --
        1998 V70 AWD Turbo 195k+








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    Removed Bevel Gear - comments on the job V70-XC70 1998

    posted by  jadnhm on  Mon Sep 21 07:52 CST 2009
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    last visit: Tue May 22 18:03 CST 2012
    [RELATED]

    Also my bevel gear does NOT have a 'vent' as is described on many of the AWD forums.

    Apparently there is a vent on newer bevel gears, and there is even an updated 'kit' that installs a better (I think longer) vent tube.
    --
    1998 V70 AWD Turbo 195k+







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