Below are some gearbox related jobs that can be done in a home workshop.
Replacing the gasket between the transfer case housing and the intermediate housing - MSG gearbox
If traces of leaks are detected in the area where the transfer case housing and intermediate housing meet, the gasket must be replaced.
1. Remove the gear shift lever as described above.
2. Place the car on stands.
3. Remove the front and rear propeller shafts as described in the appropriate section.
4. Drain the oil from the box.
5. Remove the shield under the transfer case.
Material copied from this resource: www.opelbook.ru
6. Remove the rear transmission cross member as described under transmission.
7. Disconnect the speedometer drive flexible shaft (before 1997 release).
8. Disconnect the plug connection of the speedometer with the electric drive (since 1997).
9. Loosen the bolts securing the transfer case housing from the rear side.
10. Remove the gearbox housing back together with the intermediate housing.
11. Thoroughly clean the mating surfaces of the intermediate housing and the transfer case housing
12. Connect both crankcases using a new gasket.
13. Tighten the mounting bolts evenly to a torque of 40 Nm.
14. Perform other work in the reverse order of removal.
15. Install the transmission mount cross member.
16. Finally, fill the gearbox with oil.
Replacing the rear radial oil seal of the transfer case
1. Remove the rear propeller shaft as described in the appropriate section.
2. Carefully, without damaging the crankcase, use a screwdriver to remove the MSG gearbox oil seal.
3. If the MUA transmission is installed, remove the rear flange of the drive shaft and take out the oil seal. The flange must be held from turning.
4. Lubricate the working surface of the seal with engine oil
5. Press it into the gearbox housing using a pipe.
6. If a MUA gearbox is installed, press the drive flange onto the shaft. Tighten the nut to 167 Nm. Hold the flange from turning.
7. Attach the propeller shaft.
8. Finally, check the gearbox oil level as described in the relevant subsection.
Replacing the front radial oil seal of the drive shaft of the transfer case housing - MUA gearbox
1. Remove the front propeller shaft.
2. Remove the front drive shaft flange while holding the shaft from turning.
3. Use a screwdriver to remove the oil seal, being careful not to damage the crankcase.
4. Lubricate the working surface of the seal with engine oil.
5. Press it into the crankcase using a pipe.
6. Press the flange onto the shaft.
7. While holding the shaft from turning, tighten the flange mounting nut to a torque of 137 Nm.
8. Install the front propeller shaft in place.
9. Finally, check the gearbox oil level and top up if necessary.
Replacing the speedometer drive gear
1. Disconnect the speedometer drive flexible shaft.
2. Loosen the speedometer drive gear mounting bolt
3. Remove the housing, gaskets and drive gear from the rear case.
4. Install the new gear with housing and gaskets.
5. Tighten the mounting bolt to a torque of 15 Nm.
6. Check the gearbox oil level.
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