Intermediate shaft — removal, reassembly and installation

Removing

1. First remove the right outer drive shaft as described in Chapter 2.

2. Turn off bolts of fastening of an arm of the basic bearing to the block of cylinders.

3. Using a suitable container to catch the oil, remove the countershaft from the differential and plug the opening to minimize oil loss and prevent dirt from entering the block.

Bulkhead

4. Rotate the bearing by hand, checking for smooth rotation and play. If there is any doubt about the condition of the bearing, replace it.

5. Remove the two bolts securing the flange to the bearing bracket. Remove the bracket.

6. Remove the circlip from the outer end of the layshaft, then the o-ring and large circlip holding the bearing.

7. Remove the bearing and flange assembly from the shaft. If this cannot be done manually, use a hydraulic puller or press; be careful to support the bearing inner race during removal so that the bearing can be reused.

8. Place the flange on two wooden blocks set on the work surface and push the bearing out.

9. To install a new bearing, heat it evenly using a hair dryer, for example. Using a hammer and a tubular drift the same diameter as the inner race of the bearing, install the bearing on the shaft until it reaches the shoulder of the shaft. Slide the flange onto the opposite end of the shaft and fit it onto the bearing outer race, then install the bearing circlip and then the new o-ring onto the new shaft circlip.

10. Install the bracket to the shaft assembly.

11. To ensure alignment, do not tighten the flange bolts until the shaft is installed in the differential and the bearing bracket is attached to the cylinder block (see below). After this has been done, apply a few drops of blocking compound (e.g. Vauxhall P/N 90167347) on the thread of the bolts and tighten them with a tightening force regulated specifications.

Installation

12. Installation is carried out in the reverse order of removal, paying attention to the following (see illustration):

• a) Lubricate the grooves of the shaft so as not to damage the lip of the gland when installing the shaft.
• b) Attach the bracket to the cylinder block and tighten the bolt with a tightening force regulated specifications.
• c) If the support bearing assembly has been removed, install the flange onto the bracket and tighten the two bolts (see above).
• d) Install the external drive shaft (Chapter 2).