Opel Insignia: Repair Instructions - On Vehicle

Transfer Case Fluid Replacement

Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.

2.

NOTE:

• When performing the following procedure, use only hand tools to remove and install the drain and fill plugs.
• Ensure that an approved drain pan is used when draining the transfer case.

Remove and DISCARD the oil drain plug (1) and seal.

3.

Remove and DISCARD the fill plug (1) and seal.

4. Allow the transfer case to drain completely.

Installation Procedure

1.

CAUTION: Refer to Fastener Caution.

Install a NEW drain plug (1) and seal and tighten to 50 N.m (37 lb ft).

2. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid.

3.

Install a NEW fill plug (1) and seal and tighten to 50 N.m (37 lb ft).

DRAIN PLUG REPLACEMENT

Removal Procedure

1. Remove the power transfer unit heat shield.

2.

NOTE: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs.

NOTE: Ensure that an approved drain pan is used when draining the transfer case.

Remove and DISCARD the oil drain plug (2) and seal.

3. Remove and DISCARD the fill plug (1) and seal.

4. Allow the transfer case to drain completely.

Installation Procedure

1.

CAUTION: Refer to Component Fastener Tightening Caution.

Install a NEW drain plug (2) and seal and tighten to 40 N.m (30 lb ft).

2. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid.

3. Install a NEW fill plug (1) and seal and tighten to 40 N.m (30 lb ft).

4. Install the power transfer unit heat shield.

FILL PLUG REPLACEMENT

Removal Procedure

1. Raise and suitably support the vehicle. 2. Remove the power transfer unit heat shield from the transmission. 3.

Remove and DISCARD the fill plug (1) and seal.

Installation Procedure

1. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid.

2.

CAUTION: Refer to Component Fastener Tightening Caution.

Install a NEW fill plug (1) and seal and tighten to 40 N.m (30 lb ft).

3. Install the power transfer unit heat shield to the transmission.

4. Lower the vehicle.

POWER TRANSFER UNIT VENT HOSE REPLACEMENT (2.0L LTG)

Removal Procedure

1.

Disconnect the power transfer unit vent hose assembly (1) from the radiator surge tank assembly.

2. Disconnect the power transfer vent hose assembly from the power transfer unit.

3. Remove the power transfer unit vent hose assembly (1) from the vehicle.

Installation Procedure

1.

NOTE: Ensure the vent hoses are free of kinks and routed clear of sharp objects.

Connect the power transfer unit vent hose assembly (1) to the radiator surge tank assembly.

2. Connect the power transfer unit vent hose assembly to the power transfer unit.

INTERMEDIATE DRIVE SHAFT REPLACEMENT

Removal Procedure

1. Power transfer unit cover - Remove.

2.

Remove and Discard the intermediate drive shaft retainer (1) from the transfer case.

3. Pull the intermediate drive shaft (2) out of the transfer case.

Installation Procedure

1.

Install the intermediate drive shaft (2) to the transfer case.

2. Install the NEW intermediate drive shaft retainer (1) to the transfer case.

3. Power transfer unit cover - Install.

Power Transfer Unit Cover To Intermediate Drive Shaft Seal Replacement

Special Tools

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

Equivalent regional tools: Special Tools

Removal Procedure

1. Raise and support the vehicle. Lifting and Jacking the Vehicle.

NOTE: The drive shaft remains in the wheel hub.

2. Front Wheel Drive Half Shaft- Right Side@Transfer Case - Disconnect.

3. Transfer Case Bracket - Remove.

4.

Retaining Ring(1) - Remove and DISCARD.

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

6.

NOTE: Use a flat-bladed tool (2) to remove the seal from the housing. Avoid damage to the housing seal bore or shaft sealing surface.

Power Transfer Unit Cover to Intermediate Drive Shaft Seal(1) - Remove and DISCARD.

Installation Procedure

1.

Power Transfer Unit Cover to Intermediate Drive Shaft Seal(1) - Install NEW - Use the special tool: DT- 51466 installer (2) & DT-305-1 handle (3).

2.

O-Ring(2) - Install NEW.

3. Retaining Ring(1) - Install NEW.

4. Transfer Case Bracket - Install.

5. Front Wheel Drive Half Shaft- Right Side@Transfer Case - Connect.

6. Lower the vehicle.

OUTPUT SHAFT SEAL REPLACEMENT

Special Tools

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

Equivalent regional tools:Special Tools

Removal Procedure

1. Remove the drain plug and drain the transfer unit.

2. Remove the propeller shaft.

3.

Remove and DISCARD the propeller shaft retainer (1).

4. Remove and DISCARD the propeller shaft O-ring (2).

NOTE: Use a suitable flat bladed tool 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.

5. Remove and DISCARD the transfer unit output seal (3).

Installation Procedure

1.

Using DT-51467 Seal Installer (1) and DT-305 - 1 Driver Handle (2) install the NEW transfer unit output seal.

2.

Install the NEW transfer unit propeller shaft O-ring (2).

3. Install the NEW transfer unit propeller shaft retainer (1).

4. Install the propeller shaft.

5. fill the transfer unit to the bottom of the fill plug hole with the recommended fluid.

INTERMEDIATE DRIVE SHAFT BEARING REPLACEMENT

Removal Procedure

1. Intermediate Drive Shaft Replacement - Remove.

2.

Using a press, remove the intermediate drive shaft bearing (2) from the intermediate drive shaft. Refer to power transfer unit intermediate drive shaft in Power Transfer Unit Case Disassemble.

Installation Procedure

1.

Using a press, install the intermediate drive shaft bearing (2) to the intermediate drive shaft. Refer to power transfer unit intermediate drive shaft in Power Transfer Unit Case Assemble.

2. Intermediate Drive Shaft Replacement - Install.

POWER TRANSFER UNIT FACE SEAL REPLACEMENT

Removal Procedure

1. Remove the power transfer unit from the vehicle.

2.

Remove and DISCARD the power transfer unit face seal (1) from the power transfer unit.

Installation Procedure

1.

Install the NEW power transfer unit face seal (1) to the power transfer unit.

2. Install the transfer case in the vehicle.

Transfer Case Bracket Replacement (2.0L LTG)

Removal Procedure

1. Raise and support the vehicle. Lifting and Jacking the Vehicle.

NOTE: The drive shaft remains in the wheel hub.

2. Front Wheel Drive Half Shaft- Right Side@Transfer Case - Disconnect.

3.

Remove the 2 transfer case bracket to transfer case bolts (1).

4.

Transfer Case Bracket Bolt M8(1) - Remove.

5. Transfer Case Bracket Bolt M10(3) - Remove[2x].

6. Transfer Case Bracket(2) - Remove.

Installation Procedure

1.

Transfer Case Bracket(2) - Install.

CAUTION: Fastener Caution

2. Transfer Case Bracket Bolt M10(3) - Install and tighten[2x] 58 N.m (43 lb ft).

3. Transfer Case Bracket Bolt M8(1) - Install and tighten 22 N.m (16 lb ft).

4.

Install the 2 transfer case bracket to transfer case bolts (1) and tighten to 22 N.m (16 lb ft).

5. Front Wheel Drive Half Shaft- Right Side@Transfer Case - Connect.

6. Lower the vehicle.

TRANSFER CASE BRACKET REPLACEMENT (3.6L LGX)

Removal Procedure

1. Raise and support the vehicle. Lifting and Jacking the Vehicle.

NOTE: The drive shaft remains in the wheel hub.

2. Front Wheel Drive Half Shaft- Right Side@Transfer Case - Disconnect.

3. Exhaust Front Pipe - Remove.

4. Three-Way Catalytic Converter - Remove.

5.

Remove the 2 transfer case to transfer case bracket bolts (1).

6.

Transfer Case Bracket Bolt(1) - Remove[2x].

7. Transfer Case Bracket(2) - Remove.

Installation Procedure

1.

Transfer Case Bracket(2) - Install.

CAUTION: Fastener Caution

2. Transfer Case Bracket Bolt(1) - Install and tighten[2x] 58 N.m (43 lb ft).

3.

Install the 2 transfer case to transfer case bracket bolts (1) and tighten to 22 N.m (16 lb ft).

4. Three-Way Catalytic Converter - Install.

5. Exhaust Front Pipe - Install.

6. Front Wheel Drive Half Shaft- Right Side@Transfer Case - Connect.

7. Lower the vehicle.

POWER TRANSFER UNIT CASE REPLACEMENT

Removal Procedure

1. Remove the front wheel drive half shaft.

2. Remove the three way catalytic converter. Three-Way Catalytic Converter Replacement (Bank 1) Three-Way Catalytic Converter Replacement (Bank 2).

3. Remove the transfer case bracket. 4.

Disconnect the power transfer unit vent hose (1) from the power transfer unit (2).

5. Support the power transfer unit case (2) with a suitable jack, and secure with suitable straps.

6.

Remove the 4 power transfer unit case bolts (2).

7. Remove the wiring harness bracket bolt and wiring harness bracket from the transfer case.

8. Separate the power transfer unit case from the transmission.

9.

Remove and DISCARD the power transfer unit case O-ring.

Installation Procedure

1.

Clean the contact surfaces between the power transfer unit and the transmission.

2. Install a NEW power transfer unit case O-ring (1).

3.

Support the power transfer unit case with a suitable jack, and secure with suitable straps.

4. Raise and align the power transfer unit case in the correct position in relation to the transmission.

5. Install the power transfer unit case to the transmission.

6. Position the wiring harness bracket to the power transfer unit case.

CAUTION: Refer to Fastener Caution.

7. Install the wiring harness bracket bolt and tighten to 9 N.m (80 lb in).

8.

Install the 4 power transfer unit case bolts (2) and tighten to 100 N.m (74 lb ft).

9.

Connect the power transfer unit vent hose (1) to the power transfer unit (2).

10. Install the transfer case bracket.

11. Install the front wheel drive half shaft.

12. Install the three way catalytic converter. Three-Way Catalytic Converter Replacement (Bank 1) Three-Way Catalytic Converter Replacement (Bank 2).

POWER TRANSFER UNIT HEAT SHIELD REPLACEMENT

Preliminary Procedure

Remove the three-way catalytic converter. Three-Way Catalytic Converter Replacement (Bank 1) Three-Way Catalytic Converter Replacement (Bank 2)

1. Transfer Case Heat Shield Fasteners[3x]
2. Transfer Case Heat Shield

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