Opel Insignia: Repair Instructions

Front Wheel Drive Intermediate Shaft Replacement

Removal Procedure

1. Remove the tire and wheel assembly.

WARNING: To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in damage to brake and suspension components and loss of vehicle control.

2. Front Wheel Drive Half Shaft - Remove.

3.

Intermediate Shaft Bracket Bolt(1) - Remove[3x].

4.

CAUTION: DT-51504 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install the DT-51504 as indicated may cause the splines of the wheel drive shaft to damage the differential output seal

Carefully install the DT-51504 seal protector (1) over the front wheel drive intermediate shaft (2).

5.

Front Wheel Drive Intermediate Shaft and Bracket Assembly(1) - Remove.

6.

Remove the circlip (2), and the O-ring (1), from the front wheel drive intermediate shaft.

DISCARD the circlip and the O-ring.

Installation Procedure

1.

Install a NEW circlip (2), and a NEW O-ring (1), onto the front wheel drive intermediate shaft.

2.

Front Wheel Drive Intermediate Shaft and Bracket Assembly(1) - Install.

3.

CAUTION: DT-51504 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install the DT-51504 as indicated may cause the splines of the wheel drive shaft to damage the differential output seal

Carefully install the wheel drive shaft into the differential until the splines are past the DT-51504 protector (1).

NOTE: Ensure that the front wheel drive intermediate shaft is fully seated in the transmission.

4. Remove the DT-51504 protector from the differential output shaft seal.

5.

CAUTION: Fastener Caution

Intermediate Shaft Bracket Bolt(1) - Install and tighten 58 N.m (43 lb ft)[3x].

6. Front Wheel Drive Half Shaft - Install.

7. Install the tire and wheel assembly.

Front Wheel Drive Half Shaft Replacement - Left Side

Special Tools

• J-45859 Hub Spindle Remover
• DT-51504 Seal Protector

Equivalent regional tools:Special Tools

Removal Procedure

1. Raise and support the vehicle.

2. Remove the left front tire and wheel assembly.

3. With the aid of an assistant holding the brake pedal down, use a breaker bar and the proper size socket to loosen the wheel drive shaft nut.

4.

WARNING: To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in damage to brake and suspension components and loss of vehicle control.

Wheel Drive Shaft Nut(1) - Remove and DISCARD.

5. Steering Linkage Outer Tie Rod@Steering Knuckle - Separate.

6. Lower Control Arm@Steering Knuckle - Separate.

7.

Attach the J-45859 Hub Spindle Remover (1) to the wheel hub using the wheel lug nuts.

8. Using the J-45859 Hub Spindle Remover (1), separate the wheel drive shaft from the wheel bearing/hub.

9. Remove the J-45859 Hub Spindle Remover (1) from the wheel bearing/hub.

10. Place a drain pan under the vehicle.

11.

CAUTION: Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s).

Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

Use a suitable flat bladed tool (1) to dislodge the wheel drive shaft (2) from the transmission.

12.

CAUTION: DT-51504 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install the DT-51504 as indicated may cause the splines of the wheel drive shaft to damage the differential output seal.

Carefully install the DT-51504 Seal Protector (1) over the wheel drive shaft and slide into the transmission.

13.

Wheel Drive Shaft(1) - Remove.

14.

Wheel Drive Shaft Washer(1) - Remove and DISCARD.

15.

Front Wheel Drive Shaft Retaining Ring(1) - Remove and DISCARD.

Installation Procedure

1.

Front Wheel Drive Shaft Retaining Ring(1) - Install NEW.

2.

Wheel Drive Shaft Washer(1) - Install NEW.

3.

Wheel Drive Shaft(1) - Install.

4.

CAUTION: DT-51504 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install the DT-51504 as indicated may cause the splines of the wheel drive shaft to damage the differential output seal

NOTE: Ensure that the wheel drive shaft is fully seated in the transmission.

Carefully install the wheel drive shaft into the transmission until the splines are past the DT-51504 Seal Protector (1).

5. Remove the DT-51504 Seal Protector from the transmission.

6. Install the front wheel drive shaft into the front wheel bearing/hub.

7. Lower Control Arm@Steering Knuckle - Install.

8. Steering Linkage Outer Tie Rod@Steering Knuckle - Install.

9.

CAUTION: Refer to Fastener Caution.

Wheel Drive Shaft Nut(1) - Install a NEW nut.

Tighten

1. First Pass: 150 N.m (111 lb ft)
2. Second Pass: Loosen 45 degrees
3. Final Pass: 250 N.m (185 lb ft)

10. Install the tire and wheel assembly.

11. Inspect the transmission fluid level.

12. Remove the drain pan.

13. Remove the support and lower the vehicle.

Front Wheel Drive Half Shaft Replacement - Right Side (AWD)

Special Tools

DT-45859 Axle Remover

Equivalent regional tools:Special Tools

Removal Procedure

1. Raise and support the vehicle.

2. Remove the right front tire and wheel assembly.

3. With the aid of an assistant holding the brake pedal down, use a breaker bar and the proper size socket to loosen the front wheel drive shaft nut.

4.

WARNING: To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in damage to brake and suspension components and loss of vehicle control.

Front Wheel Drive Shaft Nut(1) - Remove and DISCARD.

5. Steering Linkage Outer Tie Rod@Steering Knuckle - Separate.

6. Front Lower Control Arm@Steering Knuckle - Separate.

Attach the DT-45859 Axle Remover (1) to the front wheel bearing and hub assembly using the wheel nuts.

8. Using the DT-45859 Axle Remover (1), separate the front wheel drive shaft from the front wheel bearing and hub assembly.

9. Remove the wheel nuts and the DT-45859 Axle Remover (1) from the front wheel bearing and hub assembly.

10.

Using a suitable flat bladed tool (1), release the front wheel drive half shaft (2).

11.

Front Wheel Drive Half Shaft(1) - Remove.

12.

Wheel Drive Shaft Washer(1) - Remove and DISCARD.

13.

Retaining Ring(1) - Remove and DISCARD.

14. O-Ring(2) - Remove and DISCARD.

Installation Procedure

1.

Clean the splines of any old grease and apply a thin coat of NEW high temperature grease prior to installing the NEW O-Ring (2) and NEW Retaining Ring (1).

2. O-Ring(2) - Install NEW.

3. Retaining Ring(1) - Install NEW.

4.

Wheel Drive Shaft Washer(1) - Install NEW.

5.

NOTE: Ensure that the front wheel drive half shaft is fully seated and the retaining ring is engaged.

Front Wheel Drive Half Shaft(1) - Install

6. Install the front wheel drive shaft into the front wheel bearing and hub assembly.

7. Front Lower Control Arm@Steering Knuckle - Install.

8. Steering Linkage Outer Tie Rod@Steering Knuckle - Install.

9. Have an assistant apply the brakes.

10.

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component.

Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

CAUTION: Refer to Fastener Caution.

Front Wheel Drive Shaft Nut(1) - Install NEW and tighten

1. First Pass: 150 N.m (111 lb ft)
2. Second Pass: Loosen 45 degrees
3. Final Pass: 250 N.m (185 lb ft)

11. Install the tire and wheel assembly.

12. Remove the support and lower the vehicle.

Front Wheel Drive Half Shaft Replacement - Right Side (FWD)

Special Tools

J-45859 Hub Spindle Remover

Equivalent regional tools:Special Tools

Removal Procedure

1. Remove the right front tire and wheel assembly.

2. With the aid of an assistant holding the brake pedal down, use a breaker bar and the proper size socket to loosen the wheel drive shaft nut.

3.

WARNING: To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in damage to brake and suspension components and loss of vehicle control.

Wheel Drive Shaft Nut(1) - Remove and DISCARD.

4. Steering Linkage Outer Tie Rod@Steering Knuckle - Separate.

5. Lower Control Arm@Steering Knuckle - Separate.

6.

Attach the J-45859 remover (1) to the wheel hub using the wheel lug nuts.

7. Using the J-45859 remover (1), separate the wheel drive shaft from the wheel bearing/hub.

8. Use a suitable tool to dislodge the wheel drive shaft from the front wheel drive intermediate shaft.

9.

Wheel Drive Shaft(1) - Remove.

10.

Wheel Drive Shaft Washer(1) - Remove and DISCARD.

11.

Retaining Ring(1) - Remove and DISCARD.

12. O-Ring(2) - Remove and DISCARD.

Installation Procedure

1.

NOTE: Clean the splines of any old grease and apply a thin coat of NEW high temperature grease prior to installing the NEW O-Ring and NEW Retaining Ring.

O-Ring(2) - Install NEW.

2. Retaining Ring(1) - Install NEW.

3.

Wheel Drive Shaft Washer(1) - Install NEW.

4.

NOTE: Ensure that the wheel drive shaft is fully seated onto the front wheel drive intermediate shaft.

Wheel Drive Shaft(1) - Install.

5. Install the front wheel drive shaft into the front wheel bearing/hub.

6. Lower Control Arm@Steering Knuckle - Install.

7. Steering Linkage Outer Tie Rod@Steering Knuckle - Install.

8.

CAUTION: Refer to Fastener Caution.

Wheel Drive Shaft Nut(1) - Install a NEW nut.

Tighten

1. First Pass: 150 N.m (111 lb ft)
2. Second Pass: Loosen 45 degrees
3. Final Pass: 250 N.m (185 lb ft)

9. Install the tire and wheel assembly.

Rear Wheel Drive Shaft Replacement - Left Side

Special Tools

DT-45859 Axle Remover

Equivalent regional tools: Special Tools

Removal Procedure

1. Raise and support the vehicle.

2. Remove the left rear tire and wheel assembly.

3. With the aid of an assistant holding the brake pedal down, use a breaker bar and the proper size socket to loosen the rear wheel drive shaft nut.

4.

Rear Wheel Drive Shaft Nut(1) - Remove and DISCARD.

5.

Using the DT-45859 Axle Remover (1), separate the rear wheel drive shaft from the rear wheel bearing and hub assembly.

6. Rear Suspension Knuckle - Remove.

7.

Use a suitable flat bladed tool (1) to separate the rear wheel drive shaft (2) from the differential carrier assembly.

8.

Rear Wheel Drive Shaft(1) - Remove.

9.

Rear Wheel Drive Shaft Retaining Ring(1) - Remove and DISCARD.

10. Wheel Drive Shaft O-Ring(2) - Remove and DISCARD.

Installation Procedure

1.

Wheel Drive Shaft O-Ring(2) - Install NEW.

2. Rear Wheel Drive Shaft Retaining Ring(1) - Install NEW.

3.

Rear Wheel Drive Shaft(1) - Install.

4.

Install the rear wheel drive shaft (1) until it is fully seated into the differential carrier assembly (2).

5. Rear Suspension Knuckle - Install.

6.

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component.

Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

CAUTION: Fastener Caution.

Rear Wheel Drive Shaft Nut(1) - Install NEW and tighten

1. First Pass: 150 N.m (111 lb ft)
2. Second Pass: Loosen 45 degrees
3. Final Pass: 250 N.m (199 lb ft)

7. Install the left rear tire and wheel assembly.

8. Remove the support and lower the vehicle.

Rear Wheel Drive Shaft Replacement - Right Side

Special Tools

DT-45859 Axle Remover

Equivalent regional tools: Special Tools

Removal Procedure

1. Raise and support the vehicle.

2. Remove the right rear tire and wheel assembly.

3. With the aid of an assistant holding the brake pedal down, use a breaker bar and the proper size socket to loosen the rear wheel drive shaft nut.

4.

Rear Wheel Drive Shaft Nut(1) - Remove and DISCARD.

5.

Using the DT-45859 Axle Remover (1), separate the rear wheel drive shaft from the rear wheel bearing and hub assembly.

6. Rear Suspension Knuckle - Remove.

7.

Use a suitable flat bladed tool (1) to separate the rear wheel drive shaft (2) from the differential carrier assembly.

8.

Rear Wheel Drive Shaft(1) - Remove.

9.

Rear Wheel Drive Shaft Retaining Ring(1) - Remove and DISCARD.

10. Wheel Drive Shaft O-Ring(2)@Wheel Drive Shaft - Remove and DISCARD.

Installation Procedure

1.

Wheel Drive Shaft O-Ring(2) - Install NEW.

2. Rear Wheel Drive Shaft Retaining Ring(1) - Install NEW.

3.

Rear Wheel Drive Shaft(1) - Install.

4.

Install the rear wheel drive shaft (1) until it is fully seated into the differential carrier assembly (2).

5. Rear Suspension Knuckle - Install.

6.

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component.
Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

CAUTION: Fastener Caution.

Rear Wheel Drive Shaft Nut(1) - Install NEW and tighten

1. First Pass: 150 N.m (111 lb ft)
2. Second Pass: Loosen 45 degrees
3. Final Pass: 250 N.m (199 lb ft)

7. Install the right rear tire and wheel assembly.

8. Remove the support and lower the vehicle.

Front Wheel Drive Shaft Inner Joint and Boot Replacement

Special Tools

J-42572 Drive Shaft Seal Clamp Pliers

Disassembly Procedure

1. Front Wheel Drive Half Shaft - Remove.

• Front Wheel Drive Half Shaft Replacement - Left Side
• Front Wheel Drive Half Shaft Replacement - Right Side (AWD)Front Wheel Drive Half Shaft Replacement - Right Side (FWD)

2. Place the wheel drive shaft horizontally in a bench vise.

3.

Using a side cutter or other suitable tool, remove and DISCARD the CV boot clamps (1) from the inner CV boot.

4.

Using a suitable driver and a hammer, remove the CV joint (1) from the front wheel drive half shaft (2).

5.

Remove and DISCARD the CV boot (1) from the front wheel drive half shaft (2).

6.

Retaining Ring(1)@Front Wheel Drive Half Shaft(2) - Remove and DISCARD.

7.

Retaining Ring(1)@ Inner Joint (2) - Remove and DISCARD.

Assembly Procedure

1.

Retaining Ring(1)@Inner Joint (2) - Install NEW.

2.

Retaining Ring(1)@Front Wheel Drive Half Shaft(2) - Install NEW.

3.

Install the NEW CV boot clamps (1) and the NEW CV boot (2) onto the front wheel drive half shaft (3).

4. Pack the CV joint with grease prior to installation. Insert grease into the NEW inner boot prior to connecting the boot to the joint.

5.

Using a block of wood and a hammer, install the CV Joint (1) onto the front wheel drive half shaft (2).

6.

Compress both CV boot clamps (1) using the J-42572 Drive Shaft Seal Clamp Pliers.

7. Front Wheel Drive Half Shaft - Install.

• Front Wheel Drive Half Shaft Replacement - Left Side
• Front Wheel Drive Half Shaft Replacement - Right Side (AWD)Front Wheel Drive Half Shaft
• Replacement - Right Side (FWD)

Rear Wheel Drive Shaft Inner Joint and Boot Replacement

Special Tools

J-42572 Drive Shaft Seal Clamp Pliers

Disassembly Procedure

1. Rear Wheel Drive Shaft - Remove

• Rear Wheel Drive Shaft Replacement - Left Side
• Rear Wheel Drive Shaft Replacement - Right Side

2. Place the wheel drive shaft horizontally in a bench vise.

3.

Using a side cutter or other suitable tool, remove and DISCARD the CV boot clamps (1) from the inner CV boot.

4.

Using a suitable driver and a hammer, remove the CV joint (1) from the rear wheel drive shaft (2).

5.

Remove and DISCARD the CV boot (1) from the rear wheel drive shaft (2).

6.

Retaining Ring(1)@Rear Wheel Drive Shaft(2) - Remove and DISCARD.

7.

Retaining Ring(1) - Remove and DISCARD.

8. O-Ring(2) - Remove and DISCARD.

Assembly Procedure

1.

O-Ring(2) - Install NEW.

2. Retaining Ring(1) - Install NEW.

3.

Retaining Ring(1)@Rear Wheel Drive Shaft(2) - Install NEW.

4.

Install the NEW CV boot clamps (1) and the NEW CV boot (2) onto the rear wheel drive shaft (3).

5. Pack the CV joint with grease prior to installation. Insert grease into the NEW inner boot prior to connecting the boot to the joint.

6.

Using a block of wood and a hammer, install the CV Joint (1) onto the rear wheel drive shaft (2).

7.

Compress both CV boot clamps (1) using the J-42572 Drive Shaft Seal Clamp Pliers.

8. Rear Wheel Drive Shaft - Install

• Rear Wheel Drive Shaft Replacement - Left Side
• Rear Wheel Drive Shaft Replacement - Right Side

Front Wheel Drive Shaft Outer Joint and Boot Replacement

Special Tools

J-42572 Drive Shaft Seal Clamp Pliers

Disassembly Procedure

1. Front Wheel Drive Half Shaft - Remove

• Front Wheel Drive Half Shaft Replacement - Left Side
• Front Wheel Drive Half Shaft Replacement - Right Side (AWD)Front Wheel Drive Half Shaft Replacement - Right Side (FWD)

2. Place the wheel drive shaft horizontally in a bench vise.

3.

Using a side cutter or other suitable tool, remove and DISCARD the CV boot clamps (1) from the outer CV boot.

4.

Using a suitable driver and a hammer, remove the CV joint (1) from the front wheel drive half shaft (2).

5.

Remove and DISCARD the CV boot (1) from the front wheel drive half shaft (2).

6.

Retaining Ring(1)@Front Wheel Drive Half Shaft(2) - Remove and DISCARD.

Assembly Procedure

1.

Retaining Ring(1)@Front Wheel Drive Half Shaft(2) - Install NEW.

2.

Install the NEW CV boot clamps (1) and the NEW CV boot (2) onto the front wheel drive half shaft (3).

3. Pack the CV joint with grease prior to installation. Insert grease into the NEW outer boot prior to connecting the boot to the joint.

4.

Using a block of wood and a hammer, install the CV Joint (1) onto the front wheel drive half shaft (2).

5.

Compress both CV boot clamps (1) using the J-42572 Drive Shaft Seal Clamp Pliers.

6. Front Wheel Drive Half Shaft - Install.

• Front Wheel Drive Half Shaft Replacement - Left Side
• Front Wheel Drive Half Shaft Replacement - Right Side (AWD)Front Wheel Drive Half Shaft Replacement - Right Side (FWD)

Rear Wheel Drive Shaft Outer Joint and Boot Replacement

Special Tools

J-42572 Drive Shaft Seal Clamp Pliers

Disassembly Procedure

1. Rear Wheel Drive Shaft - Remove

• Rear Wheel Drive Shaft Replacement - Left Side
• Rear Wheel Drive Shaft Replacement - Right Side

2. Place the wheel drive shaft horizontally in a bench vise.

3.

Using a side cutter or other suitable tool, remove and DISCARD the CV boot clamps (1) from the outer CV boot.

4.

Using a suitable driver and a hammer, remove the CV joint (1) from the rear wheel drive shaft (2).

5.

Remove and DISCARD the CV boot (1) from the rear wheel drive shaft (2).

6.

Retaining Ring(1)@Rear Wheel Drive Shaft(2) - Remove and DISCARD.

Assembly Procedure

1.

Retaining Ring(1)@Rear Wheel Drive Shaft(2) - Install NEW.

2.

Install the NEW CV boot clamps (1) and the NEW CV boot (2) onto the rear wheel drive shaft (3).

3. Pack the CV joint with grease prior to installation. Insert grease into the NEW outer boot prior to connecting the boot to the joint.

4.

Using a block of wood and a hammer, install the CV Joint (1) onto the rear wheel drive shaft (2).

5.

Compress both CV boot clamps (1) using the J-42572 Drive Shaft Seal Clamp Pliers.

6. Rear Wheel Drive Shaft - Install

• Rear Wheel Drive Shaft Replacement - Left Side
• Rear Wheel Drive Shaft Replacement - Right Side

READ NEXT: