By passing the bevel gear

skibbed · Post by **skibbed** » 21 Sep 2017, 09:40

Last winter my wife's XC90 2.5T bevel gear output shaft bearing failed. She's been driving w/o issue since. I recently found what I thought was a good replacement only to find that the splines on the bevel gear input shaft were not the best. Also found that when I removed the coupler that the splines on the transmission output shaft were in the same shape. Poor design! My thought is to simply not reinstall the coupler when installing the bevel gear. Since the right axle shaft passes through the bevel gear and into the transmission differential everything should work as a fwd. I'm using the replacement bevel gear as the original gear was full of bearing material that could still destroy bearings. Any thoughts, or has anyone tried this? Thanks, Dave

Post by **ggleavitt** » 21 Sep 2017, 15:25

Can have a look here viewtopic.php?t=39119, basically the sleeve (coupler in your post I think) also acts as a seal for the transmission (2 seals actually, inner and outer) needs to remain in place so if you remove the bevel gear you'll need keep the sleeve in position (like hose clamps on the pass side driveshaft). Some variations on the theme but that's the general idea.

Good luck!

Post by **cn90** » 21 Sep 2017, 18:56

Search the internet, there are literally hundreds of these threads talking about bypassing the Transfer Case.
Whatever you do, keep the sleeve as mentioned above, even though the sleeve is damaged, you need it to seal transmission fluid.

My sleeve is stripped, I just leave the whole system alone as FWD.
This sleeve is a bad design. I don't want to spend $/time/effort only to have the sleeve stripped again.
So yes, my AWD car is now a FWD car.