Oil seals — replacement

Cardan shaft flange seal

1. See Section 8 and unfasten the front end of the propeller shaft from the flange, then remove the vibration damper (where available). If necessary, remove the shaft for easier access to the flange.

2. To block the shaft when loosening the nut, make two pieces of steel strip (one long, one short) and bolt and nut forked tool; nut and bolt form a pivot point (see illustration).



3. Lock the flange, then loosen and remove the retaining nut from the end of the transmission output shaft. Remove tool and remove flange (see illustration).



4. Note the depth of the oil seal in the transmission case, then gently pry it out using a large flat screwdriver.

5. Check the oil seal contact surface of the driveshaft flange for damage and signs of wear. If found, replace the flange.


6. Clean the area around the gland opening and remove all traces of blocking compound from the output shaft and flange nut threads.

7. Apply a small amount of grease to the outer sealing lip of the new oil seal, then rotate the oil seal with the sealing lip inward and install it on the end of the output shaft. With a suitable tubular punch (must rest only on the solid outer edge of the seal) carefully drive the oil seal to the depth measured before removing the old component.

8. Lubricate the oil seal with a small amount of gear oil, then carefully place the driveshaft flange into position, being careful not to damage the sealing lip of the oil seal.

9. Apply a few drops of blocking compound (Opel recommend using 15 10 181) on the thread of the flange mounting nut. Install the nut and tighten it with the tightening torque specified in the Specifications.

10. Install the cardan shaft as described in Section 8, then check the transmission oil level (see chapter 2).

Input shaft seal

Note: Leaks around the transmission input shaft may be caused by leakage from the input shaft oil seal or the clutch release cylinder O-ring. Replace both components regardless of their condition.

11. Remove the clutch release cylinder as described in Section 6.

12. Note the depth of the oil seal in the release cylinder, then gently pry it out using a large flat screwdriver.

13. Clean the area around the seal opening and apply a small amount of grease to the outer sealing lip of the new seal. Turn the seal so that the sealing lip is out (to the transmission block when the cylinder is installed) and install it in the cylinder to the measured depth before removing the old seal. If necessary, use a suitable tubular drift (it should rest only on the hard outer edge of the gland).

14. Replace the O-ring and install the release cylinder as described in Section 6.