Opel Insignia: Repair Instructions - Off Vehicle

Power Transfer Unit Case Disassemble

Power Transfer Unit Case Holding Fixture Installation

1. Power Transfer Unit Case

Procedure

Always secure with the pivot pin after rotating.

NOTE: The power transfer unit can be rotated 360 degrees to facilitate repair.

Special Tools

• DT-3289-20 Holding Fixture
• DT-36842 Transaxle Holding Fixture

Equivalent regional tools: Special Tools

Power Transfer Unit Heat Shield Removal

1. Power Transfer Unit Heat Shield Bolt [3x]
2. Power Transfer Unit Heat Shield

Power Transfer Unit Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Removal

1. Power Transfer Unit Oil Fill Plug

NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.

2. Power Transfer Unit Oil Drain Plug

NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.

3. Power Transfer Unit Vent Hose Connector

NOTE: Remove the vent hose connector only if replacement is required.

Power Transfer Unit Intermediate Drive Shaft Components Removal

1. Power Transfer Unit Half Shaft Retainer

Procedure

Remove and DISCARD the retainer.

2. Power Transfer Unit Half Shaft Seal (O-ring)

Procedure

Remove and DISCARD the O-ring seal.

3. Power Transfer Unit Cover-to-Intermediate Drive Shaft Seal

NOTE: Push the OD flange of the seal to remove from extension housing and shaft.

4. Power Transfer Unit Intermediate Drive Shaft Retainer
5. Power Transfer Unit Intermediate Drive Shaft
6. Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring

CAUTION: Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

7. Power Transfer Unit Intermediate Drive Shaft Bearing

Procedure

Use a press to remove the bearing from the power transfer unit intermediate drive shaft.

8. Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring

Power Transfer Unit Rear Seals Removal

1. Power Transfer Unit Propeller Shaft Retainer

Procedure

Remove and DISCARD the retainer.

2. Power Transfer Unit Propeller Shaft Seal (O-ring)
3. Power Transfer Unit Rear Output Shaft Seal

Procedure

1. Use a screwdriver to remove the seal from the housing. Remove the inner part of the seal first and then the outer part of the seal. Use care to prevent damage to the housing seal bore or shaft sealing surface. The seal is to be removed in two pieces.
2. Remove and DISCARD the seal.

Power Transfer Unit Extension Housing Removal

1. Power Transfer Unit Cover Extension Housing Bolt [10x]

Procedure

Remove and DISCARD the cover extension housing bolts. Install NEW rear extension housing bolts during assembly.

2. Power Transfer Unit Extension Housing
3. Power Transfer Unit Cover Housing Seal

Procedure

Remove and DISCARD the seal.

Power Transfer Unit Input Shaft, Idler Shaft, and Idler Shaft Tube Removal

1. Power Transfer Unit Input Shaft Assembly
2. Power Transfer Unit Idler Shaft Assembly
3. Power Transfer Unit Idler Shaft Tube

NOTE: The orientation of the tube for assembly. The end of the tube with the knurled OD area is to be facing the extension housing.

Power Transfer Unit Alignment Sleeve, Face Seal, Input Shaft Bearing Race, Idler Gear Bearing Race and Shim, and Idler Gear Shaft Tube Seal Removal

1. Power Transfer Unit Input Shaft Bearing Race - Front

NOTE: The bearing races are not an interference fit to the housing bore.

2. Power Transfer Unit Input Shaft Seal - Front

Procedure

Remove and DISCARD the seal.

Special Tools

• DT-26941 Bushing and Bearing Remover
• DT-45124 Removal Bridge

Equivalent regional tools: Special Tools

3. Power Transfer Unit Idler Gear Bearing Race - Front

NOTE: The bearing races are not an interference fit to the housing bore.

4. Power Transfer Unit Idler Gear Bearing Race Shim - Front

NOTE: The position of the shim for assembly.

5. Power Transfer Unit Idler Gear Shaft Tube O-ring - Front
6. Power Transfer Unit Locating Pins, as required [2x]
7. Power Transfer Unit Alignment Sleeve

Procedure

Discard the alignment sleeve if removed. Install a NEW sleeve during assembly.

Special Tools

• DT-44380 Differential Bearing Puller
• DT-45124 Removal Bridge
• DT-45124 - 9 Puller Legs

Equivalent regional tools: Special Tools

8. Power Transfer Unit Face Seal

Procedure

Remove and DISCARD the seal.

Power Transfer Unit Idler Shaft Bearing Race, Input Shaft Bearing Race and Input Shaft Seal Removal

1. Power Transfer Unit Idler Gear Shaft Bearing Race - Rear

NOTE: The bearing race is not an interference fit to the housing bore.

2. Power Transfer Unit Idler Gear Shaft Bearing Race Shim - Rear

NOTE: The position of the shim for assembly.

3. Power Transfer Unit Idler Gear Shaft Tube O-ring - Rear

Procedure

Remove and DISCARD the seal.

4. Power Transfer Unit Input Shaft Bearing Race - Rear

NOTE: The bearing race is not an interference fit to the housing bore.

5. Power Transfer Unit Input Shaft Bearing Race Shim - Rear

NOTE: The position of the shim for assembly.

6. Power Transfer Unit Input Shaft Seal - Rear

Special Tools

• DT-26941 Bushing and Bearing Remover
• DT-45124 Removal Bridge

Equivalent regional tools: Special Tools

Power Transfer Unit Case Cleaning and Inspection

Power Transfer Unit Case Housing Cleaning and Inspection

Preliminary Procedure

• Clean the power transfer unit case housing.
• The case halves, internal gears and bearings are not serviceable components. If damage is present, the power transfer unit must be replaced as an assembly.

1. Power Transfer Unit Case Housing Threaded Bolt Holes

NOTE: Repair any damaged threads.

2. Power Transfer Unit Case Housing Sealing Surfaces

NOTE: Repair small scratches or nicks with a soft stone.

3. Power Transfer Unit Input Shaft Seal Surface

NOTE: Inspect for thread damage or sealing surface.

4. Power Transfer Unit Idler Shaft Tube Seal Surface

NOTE: Inspect for thread damage or sealing surface.

5. Power Transfer Unit Drain Plug Hole

NOTE: Inspect for thread damage or sealing surface.

6. Power Transfer Unit Rear Output Shaft and Splines

Procedure

Rotate the shaft by hand. The shaft should rotate freely with no roughness felt within the bearings. If roughness within bearings is present, replace the power transfer unit as an assembly.

NOTE:

• Inspect the rear output shaft for end play. If end play is present, replace the power transfer unit as an assembly.
• Inspect the splines for damage or excessive wear.

Power Transfer Unit Case Extension Housing Cleaning and Inspection

Preliminary Procedure

• Clean the power transfer unit extension housing in cleaning solvent and air dry.
• The case halves, internal gears and bearings are not serviceable components. If damage is present, the transfer case assembly must be replaced.

1. Power Transfer Unit Case Extension Housing

NOTE: Inspect for excessive wear, cracks, or damage. The power transfer unit case assembly must be replaced if damage is present.

2. Power Transfer Unit Case Extension Housing Sealing Surfaces

NOTE: Repair small scratches or nicks with a soft stone.

3. Idler Gear Shaft Tube O-ring Sealing Surface
4. Power Transfer Unit Case Fill Plug Hole

NOTE: Inspect for thread damage or sealing surface.

Power Transfer Unit Input Shaft Cleaning and Inspection

Preliminary Procedure

• Clean the power transfer unit input shaft in cleaning solvent and air dry.
• The case halves, internal gears and bearings are not serviceable components. If damage is present, the power transfer unit must be replaced as an assembly

1. Power Transfer Unit Input Shaft Splines

NOTE: Inspect for excessive wear, cracks, or damage.

2. Power Transfer Unit Input Shaft - Front Seal Surface

NOTE: Inspect for pitting, excessive wear, or damage.

3. Power Transfer Unit Input Shaft Gear Teeth

NOTE: Inspect for excessive wear or damage.

4. Power Transfer Unit Input Shaft - Intermediate Drive Shaft Seal Surface

NOTE: Inspect for pitting, excessive wear, or damage.

5. Power Transfer Unit Input Shaft Bearing - Rear

NOTE: Inspect for excessive wear or damage.

6. Power Transfer Unit Input Shaft Bearing - Front

NOTE: Inspect for excessive wear or damage.

Power Transfer Unit Idler Shaft Cleaning and Inspection

Preliminary Procedure

• Clean the power transfer unit idler shaft in cleaning solvent and air dry.
• The case halves, internal gears and bearings are not serviceable components. If damage is present, the transfer case assembly must be replaced.

1. Power Transfer Unit Idler Shaft Bearing - Front

NOTE: Inspect for excessive wear or damage.

2. Power Transfer Unit Idler Shaft Gear Teeth

NOTE: Inspect for excessive wear or damage.

3. Power Transfer Unit Idler Shaft Bearing - Rear

NOTE: Inspect for excessive wear or damage.

Power Transfer Unit Idler Shaft Tube Cleaning and Inspection

Preliminary Procedure

Clean the power transfer unit idler shaft tube in cleaning solvent and air dry.

1. Power Transfer Unit Idler Shaft Tube O-ring (Front)
2. Power Transfer Unit Idler Shaft Tube

NOTE: Inspect for excessive wear or damage.

3. Power Transfer Unit Idler Shaft Tube O-ring (Rear)

Power Transfer Unit Case Assemble

Power Transfer Unit Idler Gear Shaft Tube and O-ring, Input Shaft Bearing Race and Shim, and Idler Gear Shaft Bearing Race and Shim Installation

1. Power Transfer Unit Idler Gear Shaft Access Tube O-ring- Rear
2. Power Transfer Unit Idler Shaft Tube

Procedure

The tube orientation for assembly. Install the tube with the knurled OD area facing the extension housing.

3. Power Transfer Unit Idler Gear Shaft Bearing Race Shim- Rear

NOTE: The position of the shim for assembly.

4. Power Transfer Unit Idler Gear Shaft Bearing Race- Rear

Procedure

1. The bearing races are not an interference fit to the housing bore.
2. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.

5. Power Transfer Unit Input Shaft Seal- Rear

Procedure

1. Make sure the seal bore is clean and free of oil or dirt.
2. Install the NEW seal with the notched surface of the seal facing the installer tool.
3. Install the seal onto the DT-51466 Seal Installer with the metal ID portion of the seal facing the DT-51466 Seal Installer.

Special Tools

• DT-51466 Seal Installer
• DT-305 - 1 Driver Handle

Equivalent regional tools: Special Tools

6. Power Transfer Unit Input Shaft Bearing Race Shim- Rear

NOTE: The position of the shim for assembly.

7. Power Transfer Unit Input Shaft Bearing Race- Rear

Procedure

1. The bearing races are not an interference fit to the housing bore.
2. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.

Power Transfer Unit Alignment Sleeve, Face Seal, Input Shaft Bearing Race, Idler Gear Bearing Race and Shim, and Idler Gear Shaft Tube Seal Installation

1. Power Transfer Unit Alignment Sleeve

Procedure

1. Install a NEW sleeve during assembly.
2. Use a press to install the sleeve. Install the sleeve with the tapered end facing away from case. Press the sleeve into the housing until it bottoms in the case half bore.

2. Power Transfer Unit Face Seal
3. Power Transfer Unit Input Shaft Seal- Front

Procedure

1. Make sure the seal bore is clean and free of oil or dirt.
2. Install the NEW seal with the notched surface of the seal facing the installer tool.
3. Install the seal onto the DT-51466 Seal Installer with the metal ID portion of the seal facing the DT-51466 Seal Installer.
4. Install the seal into the bore until the tool bottoms against the case half.

Special Tools

• DT-51466 Seal Installer
• DT-305 - 1 Driver Handle

Equivalent regional tools: Special Tools

4. Power Transfer Unit Input Shaft Bearing Race- Front

Procedure

1. The bearing races are not an interference fit to the housing bore.
2. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.

5. Power Transfer Unit Idler Gear Shaft Tube O-ring- Front
6. Power Transfer Unit Idler Gear Shaft Bearing Race Shim- Front

NOTE: The position of the shim for assembly.

7. Power Transfer Unit Idler Gear Shaft Bearing Race- Front

Procedure

1. The bearing races are not an interference fit to the housing bore.
2. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.

8. Power Transfer Unit Locating Pin [2x]

NOTE: Install the locating pins as required.

Power Transfer Unit Input Shaft and Idler Shaft Installation

1. Power Transfer Unit Idler Shaft
2. Power Transfer Unit Input Shaft

Power Transfer Unit Extension Housing Installation

Fig. 1: Power Transfer Unit Extension Housing Installation Tightening Sequence

1. Power Transfer Unit Cover Housing Seal

Procedure

1. Do NOT reuse the housing seal. Install a NEW seal during assembly.
2. Inspect the extension housing and main housing seal surfaces to ensure they are clean and free of damage prior to assembly.

2. Power Transfer Unit Cover Housing
3. Power Transfer Unit Cover Housing Bolt [10x]

CAUTION: Refer to Fastener Caution.

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.

Procedure

1. Clean the internal threads (no residual pre-applied adhesive allowed)
2. Use NEW bolts without pre-applied adhesive
3. Apply threadlocker to the threads of the NEW bolts.

Tighten in sequence

1. First Pass: 28 N.m (21 lb ft)
2. Final Pass:90 degrees

Power Transfer Unit Propeller Shaft Seal and Rear Output Shaft Seal Installation

1. Power Transfer Unit Output Shaft Seal

Procedure

1. Install a NEW seal.
2. Make sure the seal bore is clean and free of oil or dirt.

Special Tools

• DT-51467 - A Seal Installer
• DT-305 - 1 Driver Handle

Equivalent regional tools: Special Tools

2. Power Transfer Unit Propeller Shaft Seal

NOTE: Install a NEW seal.

3. Power Transfer Unit Propeller Shaft Retainer

Procedure

1. Install a NEW retainer.
2. When installing a NEW half shaft retaining clip, open the clip only as far as necessary to fit the clip over the shaft. Opening the clip too far will damage it.
3. Start one end of the clip in the shaft groove and slowly push the clip onto and over the shaft.

Power Transfer Unit Intermediate Drive Shaft Components Installation

1. Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring

CAUTION: Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

2. Power Transfer Unit Intermediate Drive Shaft Bearing

Procedure

Use a press to install the bearing to the shaft.

3. Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring

CAUTION: Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

4. Power Transfer Unit Intermediate Drive Shaft
5. Power Transfer Unit Intermediate Drive Shaft Retainer

Power Transfer Unit Cover-to-Intermediate Drive Shaft Seal Installation

1. Power Transfer Unit Cover to Intermediate Drive Shaft Seal

Procedure

1. Install a NEW seal.
2. Lubricate the OD area of the seal with a light film of grease or oil prior to installation.

Special Tools

• DT-51466 Seal Installer
• DT-305 - 1 Driver Handle

Equivalent regional tools: Special Tools

2. Power Transfer Unit Half Shaft Seal

Procedure

Do NOT reuse the O-ring. Install a NEW O-ring seal.

3. Power Transfer Unit Half Shaft Retainer Clip

CAUTION: When installing a new bearing retaining ring, open the ring only as far as necessary to fit the ring over the shaft. Opening the ring too far will damage it.

Procedure

Do NOT reuse the intermediate shaft retaining clip. Install a NEW clip.

Power Transfer Unit Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Installation

1. Power Transfer Unit Drain Plug

Procedure

The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.

Tighten 40 N.m (30 lb ft)

2. Power Transfer Unit Fill Plug

Procedure

1. The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
2. Tighten the oil fill plug only after the assembly has been filled with fluid.

Tighten 40 N.m (30 lb ft)

3. Power Transfer Unit Vent Hose Connector

Procedure

Apply sealant to the threads of the connector.

Tighten 20 N.m (15 lb ft)

Power Transfer Unit Heat Shield Removal

1. Power Transfer Unit Heat Shield
2. Power Transfer Unit Heat Shield Bolt [3x]

Tighten 12 N.m (106 lb in)

Power Transfer Unit Case Holding Fixture Removal

1. Power Transfer Unit Case

Special Tools

• DT-3289-20 Holding Fixture
• DT-36842 Transaxle Holding Fixture

Equivalent regional tools: Special Tools

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