Opel Insignia Owners & Service Manuals

Opel Insignia: Repair Instructions

Rear Differential Clutch Control Module Replacement

Removal Procedure

1. Prepare the control module for removal using the SPS programming support tool.

NOTE: The rear differential clutch control module can now be removed and replaced.

2. Raise and support the vehicle.

3. Differential Carrier Assembly - Drain.

4. Propeller Shaft - Remove.

5. Exhaust Muffler Assembly - Remove.

6. Rear Parking Brake Actuator - Disconnect.

7. Rear Wheel Drive Shaft - Remove.

8. Differential Carrier Assembly - Remove.

9.

Rear Drive Axle

Rear Differential Clutch Control Module Bolt(1) - Remove.

10.

Rear Drive Axle

Disconnect the connectors from the rear differential clutch control module (1 - 3).

11.

Rear Drive Axle

Rear Differential Clutch Control Module Wiring Harness(1) - Remove.

12.

Rear Drive Axle

Rear Differential Clutch Control Module(1) - Remove.

Installation Procedure

1.

Rear Drive Axle

Rear Differential Clutch Control Module(1) - Install.

2.

Rear Drive Axle

Rear Differential Clutch Control Module Wiring Harness(1) - Install.

3.

Rear Drive Axle

Reconnect the connectors from the rear differential clutch control module (1 - 3).

4.

Rear Drive Axle

CAUTION: Refer to Fastener Caution.

Rear Differential Clutch Control Module Bolt(1) - Install and tighten6 N.m (53 lb in).

5. Differential Carrier Assembly - Install.

6. Remove the hydraulic jack.

7. Rear Wheel Drive Shaft - Install.

8. Rear Parking Brake Actuator - Connect.

9. Exhaust Muffler Assembly - Install.

10. Propeller Shaft - Install.

11. Remove the supports and lower the vehicle.

12. Program the rear differential control module.

REAR AXLE LUBRICANT LEVEL INSPECTION

1. Raise and support the vehicle.

2. Clean the area around the rear axle fill plug.

3. Place a drain pan under the vehicle.

4.

Rear Drive Axle

Rear Axle Housing Fill Plug(1) - Remove.

5. Rear Axle Housing Filler Plug Gasket(2) - Remove.

6. Check the fluid level. If necessary, fill the differential to the bottom of the fill plug hole with the recommended fluid.

CAUTION: Refer to Component Fastener Tightening Caution.

NOTE: Clean and inspect the filler plug gasket (2) and replace if necessary.

7. Rear Axle Housing Filler Plug Gasket(2) - Install.

8. Rear Axle Housing Fill Plug(1) - Install and tighten 25 N.m (18 lb ft).

9. Lower the vehicle.

Differential Clutch Oil Inspection

1. Raise and support the vehicle.

2. Clean the area around the rear axle fill plug.

3. Place a drain pan under the vehicle.

4.

Rear Drive Axle

Differential Clutch Cover Plug(1) - Remove.

5. Rear Axle Housing Filler Plug Gasket(2) - Remove.

6. Check the fluid level. If necessary, fill the differential to the bottom of the fill plug hole with the recommended fluid.

CAUTION: Refer to Component Fastener Tightening Caution.

NOTE: Clean and inspect the filler plug gasket (2) and replace if necessary.

7. Rear Axle Housing Filler Plug Gasket(2) - Install.

8. Differential Clutch Cover Plug(1) - Install and tighten 25 N.m (18 lb ft).

9. Lower the vehicle.

DIFFERENTIAL OIL REPLACEMENT

Removal Procedure

1. Raise and support the vehicle.

2. Clean the area around the rear axle fill plug.

3. Place a drain pan under the vehicle.

4.

Rear Drive Axle

Rear Axle Housing Drain Plug(1) - Remove.

5. Rear Axle Housing Filler Plug Gasket(2) - Remove.

6. Allow the oil to drain completely.

Installation Procedure

1.

Rear Drive Axle

NOTE: Clean and inspect the drain plug gasket (2) and replace if necessary.

Rear Axle Housing Filler Plug Gasket(2) - Install.

CAUTION: Refer to Component Fastener Tightening Caution.

2. Rear Axle Housing Drain Plug(1) - Install and tighten 25 N.m (18 lb ft).

3.

Rear Drive Axle

Rear Axle Housing Fill Plug(1) - Remove.

4. Rear Axle Housing Filler Plug Gasket(2) - Remove.

5. Check the fluid level. If necessary, fill the differential to the bottom of the fill plug hole with the recommended fluid.

NOTE: Clean and inspect the filler plug gasket (2) and replace if necessary.

6. Rear Axle Housing Filler Plug Gasket(2) - Install.

7. Rear Axle Housing Fill Plug(1) - Install and tighten 25 N.m (18 lb ft).

8. Lower the vehicle.

DIFFERENTIAL CLUTCH OIL REPLACEMENT

Removal Procedure

1. Raise and support the vehicle.

2. Clean the area around the rear axle fill plug.

3. Place a drain pan under the vehicle.

4.

Rear Drive Axle

Differential Clutch Cover Plug(1) - Remove.

5. Rear Axle Housing Filler Plug Gasket(2) - Remove.

6. Allow the oil to drain completely.

Installation Procedure

1.

Rear Drive Axle

NOTE: Clean and inspect the drain plug gasket (2) and replace if necessary.

Rear Axle Housing Filler Plug Gasket(2) - Install

CAUTION: Refer to Component Fastener Tightening Caution.

2. Differential Clutch Cover Plug(1) - Install and tighten 25 N.m (18 lb ft).

3.

Rear Drive Axle

Differential Clutch Cover Plug(1) - Remove.

4. Rear Axle Housing Filler Plug Gasket(2) - Remove.

5. Check the fluid level. If necessary, fill the differential to the bottom of the fill plug hole with the recommended fluid.

NOTE: Clean and inspect the filler plug gasket (2) and replace if necessary.

6. Rear Axle Housing Filler Plug Gasket(2) - Install.

7. Differential Clutch Cover Plug(1) - Install and tighten 25 N.m (18 lb ft).

8. Perform the clutch system bleed procedure.

9. Lower the vehicle.

DIFFERENTIAL CARRIER BUSHING REPLACEMENT - FRONT

Rear Drive Axle

Preliminary Procedure

1. Raise and support the vehicle.

2. Remove the propeller shaft.

3. Remove the exhaust system. Exhaust Muffler Replacement (2.0L LTG) Exhaust Muffler Replacement (3.6L LGX).

  1. Differential Carrier Bushing

Procedure

  1. Support the rear differential with a jack stand.
  2. Remove the electrical connector from the rear differential clutch control module. Rear Differential Clutch Control Module Replacement.
  3. Remove the front and rear differential mounting bolts. Differential Carrier Assembly Replacement.
  4. Lower the rear differential until there is enough room to remove the differential carrier bushing.
  5. Using the DT 49126 - 1 tool and the DT 49126 - 10 kit, remove the rear differential bushing.
  6. Position the NEW rear differential bushing with the beveled edges facing the housing (up).
  7. Using the DT 49126 - 2 tool and the DT 49126 - 10 kit, install the NEW rear differential bushing.

Special Tools

  • DT 49126 - 1 Press Tool
  • DT 49126 - 2 Press Tool
  • DT 49126 - 10 Bushing Replacer Hardware Kit

Equivalent regional tools:Special Tools.

Differential Carrier Bushing Replacement - Rear

Tools Required

J-45725 Cradle Bushing Replacer

For equivalent regional tool, refer to Special Tools.

Removal Procedure

1. Raise and support the vehicle.

2. Remove the rear differential assembly.

3.

Rear Drive Axle

Mark a reference point on the frame and old bushing at the 12 and 6 o'clock position to use to align the new bushing.

4.

Rear Drive Axle

Position the J-45725-1A (1) on the bushing (2).

5. Position the J-45725-2A (1) on the frame.

IMPORTANT: Apply a small amount of grease on the threaded to lubricate the nuts when turning the nuts.

6. Install the threaded rod, bearing and washers.

7.

Rear Drive Axle

Adjust the nuts so that they are touching the J-45725-1A (2) and the J-45725-2A (1).

8. Install the proper size wrenches on the nuts.

9.

Rear Drive Axle

IMPORTANT: In the following service procedure, use only HAND TOOLS when using the J-45725 Cradle Bushing Replacer.

While holding the front wrench (1) rotate the rear wrench (2) to remove the bushing.

10. Remove the special tools.

11.

Rear Drive Axle

Remove the bushing from the frame.

Installation Procedure

1.

Rear Drive Axle

IMPORTANT: Failure to perform the following service procedure prior to the installation of the new bushing, could cause premature failure of the bushing.

Before the installation of the new bushing, use a straight edge draw a line on the new bushing at the 12 and 6 o'clock positions. Ensure that the grooves (1) are at the 12 and 6 o'clock positions.

2. Position the new bushing so that the reference marks on the frame and the bushing are in alignment. This will ensure that the new bushing will be within the 5 degree specification required for the proper alignment of the bushing.

IMPORTANT: The following procedure is to temporarily hold the new bushing in place so that the special tools can be installed for the proper installation. This is NOT to be used to install the bushing.

3. Using a block of wood and a hammer, slightly tap the bushing into the frame.

4. Assemble the threaded rod, bearings and washers as indicated in step 7 in the removal procedure.

5.

Rear Drive Axle

Position the J-45725-2 (2) on the inside of the frame.

6. Position J-45725-2A (1) on the outside of the frame.

7. Adjust the nuts so that they are touching the J-45725-2 (1) and the J-45725-2A (2).

8.

Rear Drive Axle

While holding the front wrench (2) rotate the rear wrench (1) to install the bushing.

9. Remove the special tools.

10. Install the rear differential assembly.

11. Lower the vehicle.

Rear Axle Vent Replacement

Rear Drive Axle

Preliminary Procedure

1. Raise and support the vehicle.

2. Remove the Differential Carrier Assembly.

  1. Rear Axle Vent

NOTE: Use an appropriate tool to remove and install.

REAR AXLE HOUSING VENT REPLACEMENT

Rear Drive Axle

Preliminary Procedure

1. Raise and support the vehicle.

2. Remove the Differential Carrier Assembly.

  1. Rear Axle Housing Vent

NOTE: Use an appropriate tool to remove and install.

REAR AXLE SHAFT SEAL REPLACEMENT - LEFT SIDE

Rear Drive Axle

Preliminary Procedure

Remove the left rear wheel drive shaft.

  1. Rear Axle Shaft Seal

Procedure

  1. Using a suitable tool, remove the rear axle shaft seal.
  2. Apply a small amount of lubricant to the contact area between the seal and axle.

NOTE: Remove excess lubricant from the seal.

  1. Ensure that the axle shaft seal is evenly positioned in the rear differential housing.
  2. Check the fluid level. If necessary, fill the differential to the bottom of the fill plug hole with the recommended fluid.

Special Tools

DT-51592 Seal Installer

Equivalent regional tools:Special Tools.

REAR AXLE SHAFT SEAL REPLACEMENT - RIGHT SIDE

Rear Drive Axle

Preliminary Procedure

Remove the right rear wheel drive shaft.

  1. Rear Axle Shaft Seal

Procedure

  1. Using a suitable tool, remove the rear axle shaft seal.
  2. Apply a small amount of lubricant to the contact area between the seal and axle.

NOTE: Remove excess lubricant from the seal.

  1. Ensure that the axle shaft seal is evenly positioned in the rear differential housing.
  2. Check the fluid level. If necessary, fill the differential to the bottom of the fill plug hole with the recommended fluid.

Special Tools

DT-51592 Seal Installer

Equivalent regional tools:Special Tools.

Differential Carrier Assembly Replacement

Removal Procedure

1. Raise and support the vehicle.

2. Differential Carrier Assembly - Drain.

3. Exhaust Muffler - Remove.

4. Propeller Shaft - Remove.

5. Parking Brake Actuator - Disconnect.

6. Rear Wheel Drive Shaft - Remove.

7. Disconnect the differential carrier electrical connectors at the chassis.

NOTE: Ensure that the differential carrier is securely fastened to the hydraulic jack stand.

8. Support the differential carrier with a jack stand.

9.

Rear Drive Axle

Differential Carrier Insulator Bolt(1) - Remove.

10.

Rear Drive Axle

Differential Carrier Insulator Bolt(1) - Remove.

11.

Rear Drive Axle

Differential Carrier Assembly(1) - Remove.

Installation Procedure

1.

Rear Drive Axle

Differential Carrier Assembly(1) - Install.

2.

Rear Drive Axle

Clean the bolts and apply thread locker on the threads.

CAUTION: Refer to Fastener Caution.

3. Differential Carrier Insulator Bolt(1) - Install and tighten.

  • First Pass: 80 N.m (59 lb ft)
  • Final Pass: 60-75 degrees

4.

Rear Drive Axle

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component.

Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

Differential Carrier Insulator Bolt(1) - Install and tighten

  • First Pass: 100 N.m (74 lb ft)
  • Final Pass: 30 to 45 degrees

5. Remove the hydraulic jack.

6. Rear Wheel Drive Shaft - Install.

7. Parking Brake Actuator - Connect.

8. Connect the differential carrier electrical connectors at the chassis.

9. Propeller Shaft - Install.

10. Exhaust Muffler - Install.

11. Check the fluid level. If necessary, fill the differential carrier to the bottom of the fill plug hole with the recommended fluid.

12. If installing a NEW differential carrier, fill with the recommended fluid.

13. Remove the supports and lower the vehicle.

14. Program the differential carrier control module.

LIMITED SLIP DIFFERENTIAL CLUTCH HIGH PRESSURE PIPE REPLACEMENT

Rear Drive Axle

CAUTION: It is very important to observe maximum cleanliness when working on the differential clutch. Dirt particles can seriously damage the function and service life of the differential clutch.

Preliminary Procedure

Differential Carrier Assembly - Remove.

  1. Limited Slip Differential Clutch High Pressure Pipe

WARNING: The hydraulic pressure in the differential clutch is very high. To prevent personal injury, wait for at least 10 minutes before removing any parts from the differential clutch.

Procedure

Check the fluid level. If necessary, fill the differential to the bottom of the fill plug hole with the recommended fluid.

DIFFERENTIAL DRIVE PINION GEAR SEAL REPLACEMENT

Rear Drive Axle

Preliminary Procedures

1. Raise and support the vehicle. Lifting and Jacking the Vehicle.

2. Remove the propeller shaft.

NOTE: Install a NEW differential drive pinion gear oil slinger.

3. Remove the differential drive pinion gear oil slinger.

  1. Differential Drive Pinion Gear Seal

Procedure

  1. Install a sheet metal screw into the seal.
  2. Attach a pair of pliers or a slider hammer to the screw and remove the seal.
  3. Inspect the fluid level.

Special Tools

J-24428-A Seal Installer

Equivalent regional tools:Special Tools.

DIFFERENTIAL DRIVE PINION GEAR OIL SLINGER REPLACEMENT

Rear Drive Axle

Preliminary Procedures

1. Raise and support the vehicle.

2. Remove the propeller shaft.

  1. Differential Drive Pinion Gear Oil Slinger

NOTE: Install a NEW Differential Drive Pinion Gear Oil Slinger.

Special Tools

J-33785 Installer

Equivalent regional tools:Special Tools.

REAR DIFFERENTIAL HYDRAULIC SYSTEM SERVICE FILL/BLEED

Rear Differential Hydraulic System Service Fill/Bleed Procedure

The rear differential hydraulic system service bleed is used to remove air from the system, check for proper system and solenoid function, and determine if full pressure can be achieved at the apply piston. Any time a rear differential hydraulic line is disconnected or any repairs are made, this procedure must be performed.

1. Connect scan tool and check the rear differential clutch control module for any DTCs and perform repairs as necessary. The scan tool may not allow the hydraulic system service bleed if certain DTCs are present.

2. Raise vehicle. Refer to Lifting and Jacking the Vehicle.

3. Remove the fill plug. Fill the Rear Drive Clutch fill hole to the appropriate level with the appropriate fluid.

Refer to Differential Clutch Oil Replacement, Approximate Fluid Capacities, and Adhesives, Fluids, Lubricants, and Sealers.

4. Install fill plug. Lower vehicle.

5. Ignition ON.

6. From the scan tool menu, select Rear Differential Clutch Control Module, then select Control Functions, then Rear Differential Hydraulic System Service Bleed.

NOTE: The Rear Differential Clutch Control Module can run this procedure. If this step does not pass, repeat procedure from step 2.

NOTE: Status will change to "Complete" when done.

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