Vauxhall Cavalier/Opel 4 x 4 Transfer Box Installation

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.

Source