Start
by removing the 13mm fill plug located on the rear of the housing.
Now
remove the 3-13mm nuts securing the vibration dampener on the bottom of
the housing and slide it off the studs.
This
shows the 3 studs on the bottom of the angle gear. You need to
remove the middle stud (pointing finger). No fluid will come out
removing this stud. However this is where we are going to make the
drain hole.
You
will need an angle drill (preferably a reversible one) and a 1/4"
drill bit. Apply a good bit of bearing/axle grease to the bit itself as
the above picture shows. The reason we are doing this is to catch the
metal shavings that come out while drilling.You will also want a drain
pan under the bevel gear as when your drill bit breaks through the oil
will start to run out.
Insert
the drill into the hole and slowly/carefully drill through the
casing. Keep the bit centered and do not touch the edges of the casing
while drilling. You don't want too booger up the female threads in the
bevel gear casing.
Once
the bit breaks through, reverse the drill back out and allow the fluid
to drain.
While
it's draining, take your stud that was removed and wrap the
threads with teflon tape. I also like to use a copper sealing ring as
well.
When
it's finished draining take your stud and washer then reinsert and
tighten. Slide your dampener back on and tighten.
For
refilling I use a suction device as above. I suction the fluid out
of the bottle and into the fill hole. Have your fill plug with NEW
crush washer (same as oil pan washer) ready within reach. Keep filling
until fluid starts to slightly flow out the fill hole then install the
plug and tighten. Your fluid refill should be Volvo PN# 1161648 as
shown below. You will use approx. a full container. (considering
spillage, amount drained out, etc.)
