Warning: Replacing the seal will remove the pinion bearing preload, which will then need to be adjusted. The following procedure describes how to set the preload approximately using simple tools, after which it is recommended that the dealer perform the fine adjustment of the preload.
1. Remove the final drive unit as described in Chapter 2.
2. Clamp the block in a vice.
3. Measure the pinion bearing preload as follows: fit the socket onto the pinion nut and, using a suitable torque wrench, measure the force required to make the pinion start to rotate – it should be approximately 90-120 Ncm. Record the result.
4. Apply alignment marks to the drive flange nut, flange and gear.
5. Lock the drive flange by bolting a piece of metal strip to it. Loosen the nut, counting the exact number of turns required to do this.
[Material taken from an internet portal: opelbook]
6. Using a suitable puller, pull the drive flange off the pinion.
7. Press the seal away from the main gear housing using a screwdriver. Wipe the seal's support surface in the housing.
8. Apply a small amount of differential oil (see Specifications) onto the sealing edge of the new seal, then push it into the crankcase until it is flush with the outer surface. Use a metal tube or two wooden blocks for this.
9. Install the drive flange onto the gear in its original position, then screw on the nut using the marks made during removal and the calculations performed.
10. Now it is necessary to restore the preload of the pinion bearing. Measure the force required to turn the pinion (see point 3) and adjust the position of the gear nut to achieve the desired tension.
1.1 Install the final drive unit (see Chapter 2 of this section).
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