Vauxhall Cavalier/Opel 4 x 4 Transfer Box Removal

NOTE: If you are removing the txb to replace it with another, or a different viscous coupling assembly, check the prop shaft to txb connection flanges are the same. The difference appears to be between 8 & 16v models. NOTE: The exhaust system on a non-turbo is in the centre of the vehicle and may require removal rather than simply dropping the downpipe away, as is the case with the turbo variant.
SUMMARY
1. SAFETY - FIRST DEPRESSURIZE THE ACCUMULATOR AND THEN DISCONNECT THE BATTERY(see detail item number 101
= dtn101)
2. Drain Oil from the Transfer Box (txb) and the gearbox.
3. Check necessity to disconnect the propshaft intermediate bearing housings.
4. Disconnect the Propshaft.
5. Remove & retain the offside 'cast' support bracket.
6. Remove and retain the offside drive shaft.
7. Remove and retain the inlet manifold plastic cover.
8. Disconnect & move aside, the vacuum pipe connection, brake servo to inlet manifold, at the manifold end.
9. Disconnect & move aside, the upper heater hose connection, at the cylinder head end. dtn113
10. Disconnect & move aside, the main air intake hose, at the inlet end. dtn114
11. Disconnect & move aside, the idle bypass hose, at the manifold end. dtn115
12. Disconnect & move aside, the flexible high pressure hose from the accumulator block.
CAUTION: Some ATF Fluid loss) dtn116
13. Disconnect and retain the flexible high pressure hose from accumulator block to the txb. dtn117
14. Remove and retain the 3 bolts securing the gear change plate to the top of the gearbox/txb and move the plate to one side. (Limited movement) dtn118
15. Remove and tie up the starter to one side. dtn121
16. Remove & retain the large gearbox bolt above the starter. dtn123
17. Disconnect the txb breather pipe at the txb end. dtn124
18. Remove & retain the 3 uppermost bolts from the txb

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