Vauxhall Workshop Service and Repair Manuals

Intermediate Shaft, Replace

Note:   Intermediate shaft is removed together with bracket! Process applies to: Z 17 DTH, Z 17 DTL and the petrol engines Z 20 LER, Z 20 LEL, Z 20 LEH

  Remove

1.   Remove right front wheel. 2.   Detach axle shaft from wheel hub •   Unscrew nut from axle shaft •   Counterhold with KM-468-B (1) on front wheel hub 3.   Remove tie rod from steering knuckle •   Remove tie rod nut •   Press tie rod out of steering knuckle using KM-161-B (2) together with hook KM-161-2 . 4.   Detach swing arm (3) from spring strut support tube •   Counterhold at flattened areas with open-ended wrench 5.   Detach control arm from steering knuckle •   Remove bolt (4) from guide joint •   Spread steering knuckle with KM-915 (5) •   Pull guide joint out of steering knuckle

6.   Detach brake hose from spring strut support tube •   Detach brake hose securing plate from bracket on spring strut support tube •   Unhook brake hose from bracket 7.   Press axle shaft out of wheel hub •   If necessary: use wheel hub removal tool. 8.   If present: Remove lower engine compartment cover 9.   Detach axle shaft from intermediate shaft •   Knock off intermediate shaft using soft metal drift (2) •   Remove axle shaft 10.   Remove intermediate shaft •   Detach intermediate shaft bearing bracket from engine block – Remove 3x bolts (1) •   Pull intermediate shaft out of transmission Note:   Place collecting pan underneath and collect escaping transmission fluid. 11.   Replace intermediate shaft retaining ring •   Detach old retaining ring from intermediate shaft Important:   Do not over-expand new retaining ring - otherwise intermediate shaft and retaining ring may not sit correctly in transmission. •   Carefully fit new retaining ring to intermediate shaft

  Install

12.   Install intermediate shaft •   Insert intermediate shaft into transmission •   Attach bracket for intermediate shaft mounting to engine block 55 Nm 13.   Fit right axle shaft •   Put axle shaft onto intermediate shaft Note:   Ensure that splines (1) are not damaged. •   Knock on using soft metal drift until retaining ring engages •   Insert axle shaft into wheel hub 14.   Attach guide joint to steering knuckle with new nut 50 Nm 15.   Attach swing arm (2) to spring strut support tube with new nut 55 Nm •   Counterhold at flattened areas with open-ended wrench 16.   Attach tie rod to steering knuckle with new nut 30 Nm + 90° + 15° 17.   Attach brake hose to spring strut support tube •   Place brake hose in bracket at spring strut support tube •   Fit retaining plate 18.   Fit axle shaft to wheel hub with new nut - tighten to 150 Nm , slacken to 45° , then tighten to 250 Nm •   Counterhold with KM-468-B (3) against wheel hub 19.   Attach right front wheel 110 Nm

21.	If present: install lower engine compartment cover