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Discussion Starter · #1 ·
This is how my angle gear looked when they took it off. Should this really happen to a higher end European car? It looks like it's corroded. I realize it has 120K miles on it, but still. :(

<img src="http://i1004.photobucket.com/albums/af161/andersh67_photos/Mobile%20Uploads/165_zpsg9s8hco6.jpeg" border="0" alt=" photo 165_zpsg9s8hco6.jpeg"/>
 

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Discussion Starter · #2 ·
If I have theses corrosion issues here in California where we have so little rain I wonder what problems they would have in Sweden with this car.
 

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Its not sealed from outside. So moisture gets in there
 

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It's happening because not from the angle gear, but the collar gear/spline sleeve itself, or what's left of it. The collar gear is known to fail, has wear and tear, what you see corroded are the particles from what's left of the spline teeth. Since the Angler Gear and the Transmission doesn't have a gasket, it gets damp and wet in that chamber causing the metal particles to rust. Just use a cleaner and wipe away the corrosion, the angle gear should be fine.
 

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Yep that fuzz is metal particles from the collar.
 

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Discussion Starter · #6 ·
Well, my mechanic told me the angle gear is damaged and I need a new one. I am getting a used one for $500 instead of a new for $1,900. He was saying the splines are completely gone. So you think this might not be the case?
 

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Not sure without seeing it if it's okay or not but definitely should consider welding the angle gear while your at it

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Is the shaft splines intact ? it's hard to see there seems to be a lot of particles on the teeths. It looks like there is still a good dept of teeth left, i would clean it and if they are really damaged if the bevels still turn fine i would weld a new collar in there and call it done until the whole transfer case needs replacing.

I had about 70% teeths left on mine when i changed the sleeve and it was corroded too, there is nothing you can do about it. The collar sleeve is made of weaker material so rusts gets in there and the bevel gears shaft will chew threw it over time.

Consider welding it and save money !
 

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Is the shaft splines intact ? it's hard to see there seems to be a lot of particles on the teeths. It looks like there is still a good dept of teeth left, i would clean it and if they are really damaged if the bevels still turn fine i would weld a new collar in there and call it done until the whole transfer case needs replacing.
shaft splines intact for sure. when I had mine replaced (around 90kM) I first looked and thought - look ma, teeth looks greate - then I realized that only the end of shaft and probably 1/4 on in is look ok, the rest is chewed up.

to OP - if you decide for used unit pay close attention to shaft condition. dont have pics handy but as I just said earlier the good condition of the shaft's end could be misleading.
 
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