Secrets to Installing Bevel Gears for Perfectly Smooth Spline Operation
Installing bevel gears is not a difficult task, but it is important to handle the process correctly to ensure that the gears mesh properly and provide reliable operation. Bevel gears are cone-shaped gears that use tooth-like ridges to mesh together to transmit power from one gear to another. By changing the sizes of these gears, one can also use them to manipulate the mechanical advantage of a machine, meaning that it is possible to alter the speed and torque of a driveshaft as well as the amount of power needed to turn it. Unlike most other gears, bevel gears must be mounted in perfect sync with each other, making it essential to take the time to read through the proper procedure and take each step carefully.
The first step should be to jack up your car, putting it in park to ensure that the wheels cannot roll, and then placing jack stands behind the back wheels. With the car securely in the air, place an oil pan directly beneath the gearbox, since it is likely that lubricant from the gearbox will come out when it is opened. Again using a three eighths of an inch socket wrench, remove all of the bolts securing the gearbox cover, but do not remove the topmost one until you have pried the cover open with a mallet and screwdriver. This will release the seal and cause the lubricant to pour out into the oil pan.
Now it is time to disconnect the driveshaft from the gearbox. Use a 12mm socket wrench to do this and then mark where the driveshaft bracket meets the gearbox flange using a marker or white out. This will allow the alignment of the shaft to be properly assessed upon reassembly.
Next, use a one and an eight inch socket and a breaker bar to twist and loosen the pinion nut, located within the area the driveshaft was removed from. Then with a four inch gear puller, remove the flange that sat between the pinion nut and the driveshaft. Now it is time to loosen the bolts near the bevel gears that hold the axles in place. Move the axles inward just and remove the C-clamps that keep them connected to the bevel gears. At this point, the bevel gears should slide right out, including the pinion bevel gear. This would be the ideal opportunity to replace seals and bearings, if needed.
When ready, use bolts to affix the new bevel gear and the pinion to the differential, ensuring that they are facing in the correct direction. Then reinsert the gears into the gearbox, using a backlash measurement tool to check the gear mesh. Add or remove shims to the pinion gear as necessary to align the gears properly. Once completed, it is important to lock the pinion into place with an arbor press, reposition the axles, reinstall bearings (if removed), and use loctite on the various bolts during reassembly.
The installation of bevel gears is an important step in providing reliable power transfer within a machine. Layer all the steps of the process carefully and correctly, taking breaks and double-checking work along the way, in order to ensure that the gears are mounted properly. Then, fill up the gearbox with lubricant and add a friction modifier before finally lowering the car and testing it out.
