Intermediate shaft — removal, overhaul and installation (Opel Vectra A)

Removal

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

2. Unscrew the bolts securing the support bearing bracket to the cylinder block.

3. Using a suitable container to catch the oil, remove the intermediate shaft from the differential and plug the exposed hole 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. Unscrew the two bolts securing the flange to the bearing bracket. Remove the bracket.

6. Remove the snap ring from the outer end of the intermediate shaft, then the O-ring and the large snap ring securing 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 inner bearing race during removal to ensure the bearing can be reused.

8. Place the flange on two wooden blocks placed on the work surface and press out the bearing.

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



10. Install the bracket onto 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 secured to the cylinder block (see below). Once this has been accomplished, apply a few drops of locking compound (for example Vauxhall P/N 90167347) on the threads of the bolts and tighten them with the tightening force specified Specifications.

Installation

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

• a) Lubricate the shaft grooves to avoid damaging the seal lip when installing the shaft.
• b) Apply the bracket to the cylinder block and tighten the bolt to the specified tightening torque 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 outer drive shaft (Chapter 2).