How to change the transfer box oil, rear diff, gearbox and bleed the
PAS/4x4 By Andy Kirwan & John Wild.Transfer Box oil change.
Undo the drain plug under the transfer box and drain. 8mm allen key
Leave to drain to get as much muck out the bottom as possible.
Refit drain plug.
Then remove the temperature sensor/level plug in the side of the box (14mm spanner late models).
Then fill via the breather hose in the top of the transfer box.
This should be located by the coolant tank, cable tied to the top
Straighten it out and fit a small funnel to it. Pour the fluid in.
Fill with Vauxhall synthetic 90 443 530 approx 0.6 L
Refit temperature sensor/level plug.6 speed gearbox oil change
Undo the drain plug under the gearbox and drain. 8mm allen key
Refit drain plug.
Remove the filler vent completely, located at the top of the gearbox.
It has a plastic cover on it. Unscrew with a spanner.
Fill with 1.9 L (for the 6 speed box).
Remove the level check plug in the side and check.
1.9 L SMX or Mobilube 1 syntheticRear Diff oil change
Jack up from drivers side.
Loosen the rear diff cover to let the fluid out.
Then fill with a tube through the level check plug.
0.8L of SYNTRAX or EP80 or Mobilube 1 syntheticPAS/4x4 fluid change
The PAS / 4x4 oil should be changed if black or grey.
About 1 litre of Dextron II or III
Undo jublie clip under the front radiator in the pipe that runs
to the PAS pump. Disconnect.
A load of fluid should pour out.
Then switch on ignition and press brake pedal 25 times. More fluid
should come out.
Refit and seal hose.
Remove Fuse 19
Open bypass screw on shift valve approx 3 turns. (This is the
alan key on the top of the brass block next to the accumulator)
Fill tank to MAX mark and start engine
Top up subsiding fluid level immediately to MIN mark (no more
than 1.1 litres) and allow engine to run for approx 5 minutes.
Turn steering to stop and hold in this position for approx 5 seconds
repeat process to left and right.
Close bypass screw for 20 seconds and open again
After another 20 seconds close bypass screw.
Switch off engine.
Insert fuse and switch on ignition (do not start)
Actuate brake pedal approx 25 times. (this opens and closes the
pressure switch to transfer box)
Check fluid and top up if necessary
Start engine and run for 1 minute and stop
Check fluid. (press brake pedal 25 time with ign on)