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after the escapade with the driveline noise I had earlier this year (http://www.brickboard.com/AWD/index.htm?id=1346623&show_all=1) I decided to remove my bevel gear completely (http://www.brickboard.com/AWD/index.htm?id=1374132&show_all=1) and get my bevel gear checked out by a transmission shop.
I took it to a transmission shop where they offered to give me a free estimate on rebuilding it - which I thought was great!
Unfortunately for me I didn't completely understand what I was agreeing to and they ruined it while inspecting it - they cut the bearings off the shafts inside so they now all need to be replaced before the bevel gear is useful at all again.
The good news is (for all of you) is that the bearings were ALL in EXCELLENT shape - this is on a 1998 that has almost 200k miles on it, and didn't have the bevel gear oil changed. Mind you, when I changed the BG oil when I first got the car it was disgusting and desperately needed to be changed. Also most of the seals were leaking to some degree. But the BG was really in good shape inside, despite the cooked oil residue all over everything. If I think of it I'll get pictures of the races I have left so you can see what I'm talking about.
More good news - I have read many places online where people have stated that their Volvo dealer has refused to rebuild their BG - but my trans shop guy got part numbers for ALL the bearings and seals and collars etc inside the bevel gear from the local Volvo dealer!! Again, I have read many places that Volvo dealers don't want to give this information up, so this is valuable information for anyone looking to rebuild these things when they fail.
FWIW I would say if the bearings in my BG were in such good shape, the bearings in yours are almost certainly okay as well. It's pretty expensive to replace all the bearings, but doing all the seals is not so bad.
The trans shop quoted me at ~$450 in parts and $200 in labour to put the thing back together for me.
When I think of it I will post all the part numbers on here so anyone else who needs them can find them. Once you have the part numbers you should be able to call your Volvo dealer and say "I need these parts..." and they will tell you they are a couple of days away (because they won't be stocked) but once you get them your local trans shop can put it back together for you.
Anyone out there have any opinion on whether I could rebuild this thing myself or not? Putting seals in/on is not hard, and I think I can get the bearings on with the freeze/shrink - heat/expand trick. I'm a little concerned about setting the backlash with the crown-ring-thing and the collapse-able collar...
Anyone have experience rebuilding this kind of thing at home? (nothing Volvo specific to this really) The total bill with taxes and everything comes to $725, and I am pretty sure I can get a good used one for less than that...
Any advice on this is welcomed of course.
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Here are the Volvo OEM part numbers that I got from the Trans guy (who got them from the Volvo dealer in Halifax):
I have the image scanned as well but I can't seem to upload it. If someone who knows how to upload images to this board you should a)upload my image for me and b) do a post about how to do it.
image # | Volvo # | quoted price | description
2 183841 $115 main output bearing
4 8689678 $ 13 collapsible collar
5 183839 $ 91 bearing
6 9183891 $ 17 pinion seal
9 9143885 $ 23 inner axle seal
10 30735126 $ 33 pass side axle seal
Also he listed a few other part numbers on the quote because he sourced the parts from other suppliers. I don't know the manufacturer of these parts but they are bearings:
image # | part # | quoted price | description
?? 32010X $ 82 side bearings, 2 required
?? M86647 $ 60 pinion bearing
?? HM89449 $ 46 pinion bearing
I'm not entirely sure what's up with all of these. For instance, I can't see in the diagram where the 2 side bearings are. Maybe if I get to go have a look with the parts all in front of me...
Anyway - there they are. Hope they help someone.
--
1998 V70 AWD Turbo 195k+
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Here are the Volvo OEM part numbers that I got from the Trans guy (who got them from the Volvo dealer in Halifax):
I have the image scanned as well but I can't seem to upload it. If someone who knows how to upload images to this board you should a)upload my image for me and b) do a post about how to do it.
image # | Volvo # | quoted price | description
2 183841 $115 main output bearing
3 3502104 $ 26 case, spacer
4 8689678 $ 13 collapsible collar
5 183839 $ 91 bearing
6 9183891 $ 17 pinion seal
7 9143889 $ 10 case sleeve
9 9143885 $ 23 inner axle seal
10 30735126 $ 33 pass side axle seal
11 977023 $ 4 O-ring
Also he listed a few other part numbers on the quote because he sourced the parts from other suppliers. I don't know the manufacturer of these parts but they are bearings:
image # | part # | quoted price | description
?? 32010X $ 82 side bearings, 2 required
?? M86647 $ 60 pinion bearing
?? HM89449 $ 46 pinion bearing
I'm not entirely sure what's up with all of these. For instance, I can't see in the diagram where the 2 side bearings are. Maybe if I get to go have a look with the parts all in front of me...
Anyway - there they are. Hope they help someone.
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Just some quick googling turned up some more interesting info:
The mystery bearings are TIMKEN numbers.
TIMKEN number: 32010X
this website lists it as a wheel bearing for $21 - as opposed to the quoted $82.
http://www.rockauto.com/dbphp/x,catalog,118,partnum,32010X,d,TIMKEN_32010X.html
TIMKEN number : M86647
rockauto.com has it for <$20 vs the quote at $60
http://www.rockauto.com/dbphp/x,catalog,118,partnum,M86647,d,TIMKEN_M86647.html
TIMKEN number : HM89449
this rockauto.com website seems to have good prices on bearings as it lists this one for $16 vs my quote at $46.
http://www.rockauto.com/dbphp/x,catalog,118,partnum,HM89449,d,TIMKEN_HM89449.html
rockauto lists some more parts for this car as well:
http://www.rockauto.com/catalog/x,carcode,1433999,parttype,2240
http://www.rockauto.com/catalog/x,carcode,1433999,parttype,2264
http://www.rockauto.com/catalog/x,carcode,1433999,parttype,2380
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I hope I never need that information, but thanks for sharing it. Good stuff.
Did some searching on those non-Volvo part numbers. All three are Timken part numbers/ It looks like they are used in a lot of differentials and gearboxes (from Honda to Ford to Porsche).
Timken has some great catalogs and information on their website. Worth a look-see especially if one plans to DIY.
-Will
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854 - 244 - Mini
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So what is the part that makes the noise?
-Will
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854 - 244 - Mini
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haha that is a good question.
I don't think it was coming actually from the bevel gear. A close inspection of the center prop shaft's carrier bearing makes me think the noise was coming from there and moving up the prop shaft to the bevel gear area.
As I said before, I never intended for the BG to be completely torn down, I wanted him to have a look and let me know if he could source the bearings and seals and put it back together... now it's ruined though.
There has been some talk that for some people the large main gear is travelling on the main shaft... there was no indication of that whatsoever on mine.
Also there was no discolouration or pitting on any bearing races, and there was no chipping or adverse wear on the gears.
This part seems to be a bit of an enigma so I think when I get around to posting the part numbers I'll also try to post some pics of what this thing looks like inside. The more information the better.
What is it they say over at MAKE magazine: "If you can't open it, you don't own it" lol
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Over on V70R.com and XC70.com they mention the splines in the shaft wearing down. Any mention on this aspect of the rebuild? Perhaps it is just the "R" models with 300bhp that put too much stress on the shaft.
Nice to know about the bearings, but changing the BG oil is a requirement in my book.
Klaus
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Proud owner of a 1967 220S
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I didn't notice the splines and the trans guy didn't mention them either though I don't think I asked about them directly. Do you mean the splines on the small intermediate shaft that transfers power to the bevel gear or the actual shafts that are inside the bevel gear?
I agree that the oil change is a requirement. I only brought up the good condition of mine to lead people to blame this gearbox as a last resort. Mine has been abused and actually held up marvelously. Perhaps those with the more powerful engines are in a different category. The oil I took out of mine was terrible. Gear oil smells bad when it's brand new but this was just unreal. And BLACK.
Another thing I noticed with the case off was that the 'drain' I installed was really in the perfect spot. It's a great solution to the problem, and people should not feel reluctant about doing this job - there is nothing on the inside of that part of the case to run into. Be careful of course, but it's really a good solution.
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small intermediate shaft that transfers power to the bevel gear
--
Proud owner of a 1967 220S
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Klaus is refering to larger set of splines on a collar about 2.5" in diameter. The coupler itself wears out - generally on the BG side and the splines on the BV themselves wear which necessitates replacement of a hard part during the rebuild. In my experience I haven't seen BG's cause a problem themselves, but they get destroyed when a viscous coupler starts to bind or when mismatched tires are put onto a car. They can and do explode in a mater of miles. Splined coupler is about $100 from Volvo - would highly recommend replacing. I think the splines on the BG are part of the primary sidways shaft which I bet it pretty pricey. I just install everythin new from Volvo.
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I think the collar you're referring to is what I was calling the 'intermediate' shaft. It's about 2.5" in diameter and polished on the outside and splined on the inside. It fits between the transmission and the bevel gear, and the pass side driveshaft goes right through it.
There is a picture of one still in the transmission here:
http://i27.photobucket.com/albums/c190/huseinholland/cars%20cats%20houses/T5install0049.jpg
Are we talking about the same thing?
You said you order this shaft from Volvo? what is the part number of this shaft?
Have you rebuilt one of these things from the inside out? Is setting the backlash and setting the collapsible collar something a good wrench-spinner can handle at home?
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yeah I don't imagine you have had bearing trouble - as I said my bearings were all in great shape and it's a shame the trans shop guy tore them all apart.
I think if mine were in good shape, everyone's will be. As I said, mine was abused a bit by not having the oil changed for the first 10 years/200k of its life.
--
1998 V70 AWD Turbo 195k+
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That's the thing. Only part number I have around is 9181408 - not sure it'll fit your application, but it might point you in the right direction. Splines on both this coupler/sleeve and the shaft on the BG should have the profile of a triangle - not the Eifel Tower.
Never rebuilt one. Thanks for the parts numbers, though. Handy. Like I say, never had bearing troubles, always stripped splines on horizontal shaft which engages above coupler/sleeve.
More common on heavier second gen XC70 and most common on XC90. Don't think horsepower plays too much of a factor. More dependent on vehicle weight and driving habits.
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