At a run of about 80,000 km, the axle shafts must be replaced as a set.
There are weights on the right axle shaft on some vehicle variants. When installing them, ensure that the proper distance from them to the cover is maintained.
Removing
Engage any gear, tighten the parking brake. Loosen and loosen the castellated hub nut.
Attention! The car must be on the ground, otherwise it may fall!
Loosen the front wheel bolts.
Raise the front of the car.
Remove the front wheel, having previously marked its position relative to the hub.
Unscrew the castellated nut and press out the support with a conventional puller or Opel KM-507-C tool (see fig. D0012).
Knock the half shaft out of the hinge housing. In workshops, a special device and a hammer weighing 1.5 kg are used for this.
Attention! The face of the fixture must face the gearbox.
In vehicles with F-10/F-13 gearboxes (1.4/1.6 L engines): knock out the axle shafts from the gearbox housing on both sides manually using the KM-460-2-A tool.
In vehicles with F-16 gearbox (1.8/2.0 L engines): knock out the left axle shaft using the KM-503-A tool, and the right axle shaft - KM-460-A. In all-wheel drive vehicles, knock out the left axle shaft using the KM-503-A tool, and the right axle shaft with a drift.
When removing the axle shaft, oil flows out, so the hole in the gearbox must be closed with an appropriate plug (e.g. Opel ET N9092869).
If there are no special tools or the axle shaft sticks, knock it out with a flat punch, after removing the cover from the differential.
Attention! This causes oil to leak out. Insert a flat drift between the end of the axle shaft and the axis of the bevel gear and knock out the axle shaft.
Tie the half shaft on the wire.
Remove axle shaft from wheel hub.
Attention! After removing the axle shaft, you must not load the front wheel or move the car, as this will knock off the installation of the thrust ball bearing. If you still need to move the car, be sure to insert the axle shaft shank into the hub and tighten the castellated nut.
For all work requiring the removal of the axle shaft from the gearbox housing, efforts should only be applied to the axle shaft hinge, and not to the axle shaft itself. When removing the axle shaft from the hub, the same rule should be observed with respect to the internal hinge.
Installation
Attention! Be careful with the new axle shaft. It should not lie on protective covers for a long time.
The connecting surfaces of the outer joint and the axle shaft at the ball bearing of the front hub must be absolutely clean.
Lubricate the splines and seating surfaces of the bearings with oil.
Insert the axle shaft into the splines of the hub. Put on a new washer and castle nut and tighten the latter.
Lubricate the mounting location of the axle shaft in the differential housing with oil.
Press the axle shaft into the differential housing by hand, and then drive the retaining ring with a screwdriver until it snaps into place. To do this, put a screwdriver on the edge of the weld, but not on the cladding.
After snapping the retaining ring into place, check that the joint is firmly seated by pulling it out by hand.
If the differential cover was removed, install it with a new gasket, gluing the latter to the cover with bearing grease. Tighten bolts to 30 Nm.
Add oil to the gearbox.
Insert the tip into the steering knuckle and tighten the slotted nut to 70 Nm. Insert and bend new cotter pin.
Install the front wheel, observing the previously marked markings.
Set at distance 1 (equal to 267 mm) from the tide of fastening the cover' external hinge 2 compensation weight.
Lower the car.
Tighten wheel bolts crosswise to 110 Nm.
Tighten the hub nut to 130 Nm. Then loosen the nut and tighten it to 20 Nm. In this position, tighten the nut an additional ¼ turn.
Insert a new cotter pin and bend; Loosen the slotted nut (not tighten) to the nearest hole.
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