Bevel Box

[captain jack]

I had the bevel box off & come to refit & hit a problem in offering the box to the shaft. The manual states that the internal sleeve should be pulled forward to lift the splined end of the shaft off the bottom of the drive shaft tube thus enabling the splined collar of the bevel box drive to connect with the drive shaft. So having looked around in there & felt around with finger & fish wire I find there is no sleeve & what's more the dealers official manual makes no mention of it. Has anyone out there had a similar experience & if so how did you manage to locate it? I shall probably never have the thing off again (or at least hope not)but i would like to know how you managed it. I've got mine back on using a length of soft vinyl tube to lift the shaft & being soft it allowed the bevel box to fit on by squashing the tube and allowing me to pull it out once located, I'm sure there are better ways, just wondered what they are.

 

[ruzzle]

The earlier models did not have the sleeve.

There have been various tricks tried to hold up the shaft while offering up the bevel box. Most of them involve bits of fishing line or something that can be pulled out once the splines engage.

Someone actually put a small ice block under the shaft, figured it would melt and not be a problem.....

 

[Rocket Scientist]

I shall probably never have the thing off again (or at least hope not)but i would like to know how you managed it.

You should take it off every tire change (motorcycle tire) or not more than 10,000 miles with a darkside, to grease the splines. VERY important !

 

[UNCLE JESSE]

After I cleaned and put the lubrication on the splines mine had a spring that helped guide it back together no problem

 

[Rocket Scientist]

After I cleaned and put the lubrication on the splines mine had a spring that helped guide it back together no problem

Same here.

 

[captain jack]

I've seen the posts in the past about the state of the shaft & tube, but I've done 30,000 miles & this is the first time its been off & its in fine condition, beautifully clean & lubricated but now of course it has all new grease. It does have the said "springy thing" but I don't see how that helps with locating things & I don't know what years are classed as early models but mines 09 & as I said the sleeve is not referenced in the dealers latest manual. Whether it comes off again or not I shall have made a tool for it just to be ready. Thanks for the replies.:bch:

 

[mpr54]

Bevel Box Filler Torque

Factory manual calls for torque of 60 nm for filler plug - sounds high. Any suggestions?? Also - are compression washers required - mine had none.
Thank you.

 

[warp9.9]

I had the bevel box off & come to refit & hit a problem in offering the box to the shaft. The manual states that the internal sleeve should be pulled forward to lift the splined end of the shaft off the bottom of the drive shaft tube thus enabling the splined collar of the bevel box drive to connect with the drive shaft. So having looked around in there & felt around with finger & fish wire I find there is no sleeve & what's more the dealers official manual makes no mention of it. Has anyone out there had a similar experience & if so how did you manage to locate it? I shall probably never have the thing off again (or at least hope not)but i would like to know how you managed it. I've got mine back on using a length of soft vinyl tube to lift the shaft & being soft it allowed the bevel box to fit on by squashing the tube and allowing me to pull it out once located, I'm sure there are better ways, just wondered what they are.

Jack just stick the bevel box up in the tube and start to rotate it at the same time apply a little pressure you will be able to pick it right up and when it engauges the splines she will slide right in. Use the proper torque sequence per manual when bolting her in.

 

[muleskinner]

There are no crush washers on either drain or fill bolts from the factory. I use Loctite thread sealer like you would use on transmission or rear axle plugs. Be careful not to tighten the plugs too tight. Some here will attest to breaking them off in the housing!

 

[pete.triumph]

I've seen the posts in the past about the state of the shaft & tube, but I've done 30,000 miles & this is the first time its been off & its in fine condition, beautifully clean & lubricated but now of course it has all new grease. It does have the said "springy thing" but I don't see how that helps with locating things & I don't know what years are classed as early models but mines 09 & as I said the sleeve is not referenced in the dealers latest manual. Whether it comes off again or not I shall have made a tool for it just to be ready. Thanks for the replies.:bch:

done mine at 20,000 km (12,000 miles) for the first time it was dry and rusty with dry gunk I used the head of a cable tie to hold up shaft to slide in spleen then pulled cable tie out, worked well got it first go