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.