Opel Insignia: Repair Instructions

PROPELLER SHAFT REPLACEMENT

Special Tools

• DT-51329 Drive Shaft Remover
• GE-2619-A Slide Hammer

Equivalent regional tools:Special Tools.

Removal Procedure

1. Raise and support the vehicle.

2.

Floor Panel Tunnel Panel Front Brace(3) - Remove.

3.

Floor Panel Tunnel Panel Rear Brace(2) - Remove.

4. Exhaust Muffler - Remove.

5.

Mark the relationship of the propeller shaft front end (1) to spline interface at the differential carrier assembly and the power transfer unit using a paint pen.

6.

Mark the relationship of the propeller shaft (1) to spline interface at the differential carrier assembly using a paint pen.

7.

Mark the position of the front and rear propeller shaft bearing supports (1) using a paint pen.

8. Loosen the 2 rear propeller shaft bearing support bolts (2), but do not remove.

9.

CAUTION: When removing the propeller shaft, DO NOT pry against the power transfer unit. The power transfer unit will be damaged if it is pried against, which will result in unnecessary replacement of the power transfer unit.

Install the DT-51329 Drive Shaft Remover (1)in the service groove of the propeller shaft (2) at the power transfer unit.

10.

CAUTION: When removing the propeller shaft, DO NOT pry against the power transfer unit. The power transfer unit will be damaged if it is pried against, which will result in unnecessary replacement of the power transfer unit.

Using the DT-51329 Drive Shaft Remover (1) and the GE-2619-A Slide Hammer remove the propeller shaft from the power transfer unit.

11. Support the propeller shaft with a suitable jack stand.

12.

Remove the 2 propeller shaft bearing support bolts (1) at the rear propeller shaft bearing support (2).

13.

Propeller Shaft(1)@Power Transfer Unit Rear Output Shaft(2) - Remove.

14.

CAUTION: When removing the propeller shaft, DO NOT pry against the rear differential module slinger. Prying against the rear differential module slinger may cause damage to the slinger, which will result in unnecessary replacement of the rear differential module slinger.

Install the DT-51329 Drive Shaft Remover (1)in the service groove of the propeller shaft (2) at the differential carrier assembly.

15.

Using the DT-51329 Drive Shaft Remover (1) and the J-2619 - 01 Slide Hammer disengage the propeller shaft from the differential carrier assembly.

16.

Propeller Shaft(1)@Differential Carrier Assembly(2) - Remove.

17.

Propeller Shaft(1) - Remove.

18.

Retaining Ring(1)@Power Transfer Unit Rear Output Shaft - Remove and DISCARD.

19. O-Ring(2)@Power Transfer Unit Rear Output Shaft - Remove and DISCARD

20.

Retaining Ring(1)@Differential Carrier Assembly - Remove and DISCARD.

21. O-Ring(2)@Differential Carrier Assembly - Remove and DISCARD.

Installation Procedure

1.

NOTE: Care must be taken when installing the O-ring correctly. Ensure it is not twisted or distorted and is properly seated in the correct machined groove of the power transfer unit.

O-Ring(2)@Power Transfer Unit Output Shaft - Install NEW.

NOTE: Walk on the retaining ring to avoid distortion.

2. Retaining Ring(1)@Differential Carrier Assembly - Install NEW.

3.

NOTE: Care must be taken when installing the O-ring correctly. Ensure it is not twisted or distorted and is sitting properly seated in the correct machined groove of the differential carrier assembly.

O-Ring(2)@Differential Carrier Assembly - Install NEW.

NOTE: Walk on the retaining ring to avoid distortion.

4. Retaining Ring(1)@Differential Carrier Assembly - Install NEW.

5.

NOTE: Install the front propeller shaft to the power transfer unit referencing the marks. When the propeller shaft is correctly installed an audible click can be heard from the c-clip. Then ensure that front shaft is fully engaged by firmly pulling on the front tube. Then install the rear by aligning the reference marks and ensure that the rear shaft is fully engaged into the differential carrier assembly, again by listening for an audible click and then by firmly pulling on the rear tube. Do not use leverage to seat or when checking to see if fully seated.

Propeller Shaft(1) - Install.

6.

Install the front of the propeller shaft (1) to the power transfer unit referencing the marks. When the shaft is correctly installed an audible click can be heard from the retaining ring (2). Ensure that the shaft is fully engaged by firmly pulling on the front tube. Do not use leverage to seat or when checking to see if fully seated.

7.

Install the rear of the propeller shaft (1) by aligning the reference marks and ensure that the rear of the shaft is fully engaged into the differential carrier assembly. Listen for an audible click from the retaining ring (2) for proper installation. Ensure that the shaft is fully engaged by firmly pulling on the rear tube. Do not use leverage to seat or when checking to see if fully seated.

8. Prepare the bolts for installation as follows:

1. Remove all traces of the adhesive patch from the bolts and the mating threads using the appropriate tools.
2. Clean the threads of the bolts and mating threads with denatured alcohol or equivalent and allow to dry.
3. Apply thread locking adhesive to the bolts. Adhesives, Fluids, Lubricants, and Sealers
4. Ensure there are no gaps in the thread locking adhesive once applied to the bolt.

9.

Loosely install the 2 propeller shaft bearing support bolts (1) at the rear propeller shaft bearing support (2).

10.

Align the front and rear propeller shaft bearing supports (1) to the marked positions.

CAUTION: Refer to Fastener Caution.

11. Tighten the 2 propeller shaft bearing support bolts (2) at the rear propeller shaft bearing support (1) to 58 N.m (43 lb ft).

12. Conduct a retention check on the propeller shaft front and rear interface. Place hands around the propeller shaft tube just behind the interface and firmly pull on the propeller shaft tube without using leverage or body weight. The intention is to check that the snap ring has snapped into position, not to forcefully remove a correctly installed propeller shaft. Verify the O-ring is still seated in the groove and the paint marks are aligned correctly.

13. Exhaust Muffler - Install.

14.

Floor Panel Tunnel Panel Rear Brace(2) - Install.

15.

Floor Panel Tunnel Panel Front Brace(3) - Install.

16. Remove the support and lower the vehicle.

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