Vauxhall Opel Cavalier 4×4 Transfer Box PDF Installation Instructions Manual

This procedure assumes the removal procedure has been read and/or followed. CAUTION: If you followed the removal procedure, the gearbox may NOT have any oil in it – do not forget. 500. Inspect the txb (Transfer box) before reinstalling, Clean off any excess jointing compound. 501. Lightly apply grease to the flange of the txb to gearbox coupling (two visible splined shafts), and apply the rubber ‘O’ ring to the flange. 502. Apply masking tape (Fig.1B) or similar to the fluid coupling and the txb breather/filler connections to prevent ingress of unwanted material while installing the txb. 503. Clean all set aside bolts in readiness for Loctite fluid when required and loosely place two bolts (Fig.1A) to protect the temp sensor, if fitted, and to tie the cable. 504. Prepare the vehicle by placing a trolley jack ready to lift the txb into position. The jack will need to manoeuvre easily to facilitate mating the txb to the gearbox. 505.

If the temperature sensor is not fitted, temporally plug the opening with a length of non-fluffy rag, and insert a grease plug into the two adjacent mounting holes to prevent ingress of dirt. If the temperature sensor is fitted it is recommenced the cabling be coiled up and tied to a loosely inserted mounting bolt. In addition another mounting bolt should be loosely located in the adjacent location to help prevent damage during installation. (£62) 506. Carefully place the txb in position on the trolley jack and manoeuvre to a position below the fitting area. CAUTION: At no time allow yourself to come between the txb and the ground as the txb is very heavy. You are advised to wear heavy duty gloves while manoeuvring the txb into position, to protect your hands. 507. Jack the txb into position (Fig.2 & 3) so it can be slid into the gearbox opening. This is a difficult manoeuvre as the rear of the sump is not straight.

Angle the txb up at the back so as to insert the propshaft end over the visible torsion bar. Take care not to damage the splined shafts. 508. As the rear of the box gets into position (photo), the front can be tilted into position to allow the box to be slid home into the gearbox opening. This will engage both the drive shaft extension shaft and the txb drive shaft. CAUTION: It is essential to keep the weight of the txb on the trolley jack as there are no centering sleeves in the gearbox. 509. As the txb slides into place, applying Loctite to the mounting bolts and loosely fix with the lowest bolt (Fig.2A) to keep it in position (Fig.4A & B). Once mated to the flange with the previously greased ‘O’ ring, the weight is not so critical. NOTE: Of the five lower mounting bolts, the rearmost bolt (not illustrated) is slightly longer than the rest and is the one inserted in the opposite direction to the remaining four. 13mm spanner. 510. Apply Loctite and insert the remaining two lowest bolts, There are two further bolts which will be placed later. (See para. 522) 511. Remove and take away the trolley jack. 512. Apply Loctite and insert the three bolts (Fig.5A & B) at the top of the txb, two short top & front and the longer bolt to the rear. The latter bolts from the gearbox to the txb.

Tighten all eight mounting bolts. CAUTION: Make sure the spanner used is in good condition and a good fit. The 13mm bolts were actually a better fit with a 1/2″ AF ring spanner, on the specimen vehicle. 13mm and/or 1/2″ AF spanners. 513. Place the starter back into position (Fig.6A). The top bolt includes a bracket to hold the starter cabling in position. Loosely tighten the bolt. It will be removed later to fit the hose bracket. 19 mm spanner. 514. From under the vehicle insert the lower starter bolt and loosely tighten. 17mm + short extension. 515. Re-attach the starter support plate, two small nuts & washers at the starter and one bolt to the engine block, tighten all three mounting bolts and the lower starter mounting bolt. 8mm & 13mm spanners. specimen vehicle. If the temperature sensor was removed then withdraw the temporary cloth plug from the mounting hole and reinsert the temperature sensor with its copper washer. This is further facilitated by removing the adjacent and lower txb to gearbox mounting bolt. CAUTION: This item is fragile and can be easily damaged – (£62). Keep the cabling from being damaged by twisting. 19mm spanner & DC Test Meter. 517. Using a small piece of wire fish out the grease plug from the two mounting holes of the txb, adjacent to the temperature sensor. Wire. 518. Offer the offside cast support bracket to the txb / engine block. Loctite and Loosely fit the three mounting bolts, bracket to txb. NOTE: The lower mounting bolt hole will be used for txb oil level checking later. 13mm spanner. 519. Place the two mounting bolts, which are visible, into place – support bracket to engine block.

The third mounting can only be accessed with a socket on a short extension bar and includes the bottom mounting of the inlet manifold to engine block support bar. Place the bolt into the bar and manoeuvre into position, use the socket to drive the bolt home. Reach up to the inlet manifold and insert the bolt into the other end of the support bar. 8mm & 13mm spanner. 520. Tighten all six of the txb cast support bracket and the upper bolt of the inlet manifold to engine block support bracket. 13mm & 15mm spanner. 521. Route the temperature sensor cable to the bulkhead by passing it between the steering rack bellows and the torsion bar, and then behind the remaining pipe work to the bulkhead. Locate the connector, towards the nearside and make the connection. Check the slack required for the cable and use cable ties to keep the excess in the bulkhead run. The cable should now be clipped to the cast support bracket. (Fig.8B) Small cable ties. 522. Apply locktite to the remaining two lower txb to gearbox mounting bolts and place in position and tighten. (Five bolts in all – see para. 510) 523. Replace the large bolt engine block to gearbox, adjacent to the upper starter bolt. 19mm spanner. 524. Apply Loctite and replace the three bolts to secure the gear change mechanism into place. The longest bolt is towards the front of the vehicle and of the two shorter bolts, one has a clip associated with it and goes to the nearside of the two. Do not tighten this one fully until the txb fluid pipe is clipped into position. 525.

Remove the protective tape from the txb filler/breather pipe connection, clean the pipe and attach to the top of the txb. 526. Remove the protective tape from the txb high pressure connection. Route the high pressure hose to the olive connection, clip the pipe into the clip (para. 524) and temporarily tie the pipe in a vertical position against one of the ABS brake pipes (Fig.7B). Tighten the olive connection and finally tighten the gearbox mounting bolt with the clip associated. 13mm & 17mm, Cable tie. 527. Carefully introduce DEXTRON II ATF fluid to the top of the secured high pressure hose (para. 526 & Fig.7B). Place small polythene bag over the connection and leave. This is to facilitate air rising and escaping (bleeding) from the clutch pressure plate assembly and the associated pipe. Top up as air is displaced. DEXTRON II ATF Fluid. 528. Start connecting the previous removed connections which improved the working space. a. Large vacuum pipe, brake servo to inlet manifold – manifold end. b. Air by-pass hose inlet manifold to by-pass motor valve – manifold end. c. Inter-cooler hose, inter cooler to inlet manifold – both ends. d. Lower heater hose to water manifold connection, water manifold end, under inlet manifold. Screwdriver. 529. Re-check level of DEXTRON II in the high pressure hose and replenish as necessary. (para. 527) 530. Remove the upper most starter securing bolt and refit the multi-hose support bracket. Tighten the starter bolt and insert both heater hoses to the support bracket along with the clutch cable. Refit one end of the….

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