Download Opel Vauxhall Cavalier/ Opel 4 x 4 transfer box removal pdf

Filename: Opel Vauxhall Cavalier/ Opel 4 x 4 transfer box removal pdf
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Vauxhall Cavalier/Opel 4 x 4 transfer box removal NOTE: If you are removing the txb to replace it with another, or a different viscous coupling assembly, check the prop shaft to txb connection flanges are the same. The difference appears to be between 8 & 16v models. NOTE: The exhaust system on a non-turbo is in the centre of the vehicle and may require removal rather than simply dropping the downpipe away, as is the case with the turbo variant. SUMMARY 1. SAFETY – FIRST DEPRESSURIZE THE ACCUMULATOR AND THEN DISCONNECT THE BATTERY (see detail item number 101 = dtn101 ) 2. Drain Oil from the Transfer Box (txb) and the gearbox. dtn103 3. Check necessity to disconnect the propshaft intermediate bearing housings. dtn105 4. Disconnect the Propshaft. dtn106 5. Remove & retain the offside ‘cast’ support bracket. dtn107 6. Remove and retain the offside drive shaft. dtn108 7. Remove and retain the inlet manifold plastic cover. dtn111 8. Disconnect & move aside, the vacuum pipe connection, brake servo to inlet manifold, at the manifold end. dtn112 9. Disconnect & move aside, the upper heater hose connection, at the cylinder head end. dtn113 10. Disconnect & move aside, the main air intake hose, at the inlet end. dtn114 11. Disconnect & move aside, the idle bypass hose, at the manifold end. dtn115 12. Disconnect & move aside, the flexible high pressure hose from the accumulator block. CAUTION: Some ATF Fluid loss) dtn116 13. Disconnect and retain the flexible high pressure hose from accumulator block to the txb. dtn117 14. Remove and retain the 3 bolts securing the gear change plate to the top of the gearbox/txb and move the plate to one side. (Limited movement) dtn118 15. Remove and tie up the starter to one side. dtn121 16. Remove & retain the large gearbox bolt above the starter. dtn123 17. Disconnect the txb breather pipe at the txb end. dtn124 18. Remove & retain the 3 uppermost bolts from the txb CAUTION: Good fitting spanners essential dtn125 to dtn127 19. Remove & retain the five bolts securing the txb to gearbox, from underneath the vehicle. (Leave the lowest in place until ready to remove the txb). dtn128 20.
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