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Insignia transferbox / transfercase / PTO unit oil change

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  • Insignia transferbox / transfercase / PTO unit oil change

    With 125.000km I decide to change TRANSFER BOX (Transfer case, Power take off unit...) oil. Opel(Vauxhall) state that it is "fill for life" (it is also stated for rear differential, Haldex coupling, automatic transmmision AF40, power steering itc.- so you dont need to change anything )
    IMPORTANT! This is for transfer box for AT AF40 with 4x4, on other models it could be other fluid, so check manual/part catalog!!!

    First you need oil, GM 1940777 or 93165383 ,very expensive 60-70eur/1L.
    It is gear oil 75W-90 with spec MIL-L-2105D / GL5 /MT-1, newer is MIL-PRF-2105E or even newer SAE J2360.
    There are aftermarket oils for 15-25eur/1L:
    MOTUL Gear 300 75W-90 (300 LS also, but LS is mainly for rear diferential)
    LM 4434 Gear Oil SAE 75W-90
    MARLY GL5 75W-90
    FEBI BILSTEIN 32590
    RAVENOL VSG SAE 75W-90
    ROWE Hightec Topgear 75W-90 S
    KROON SP Gear 1071

    So let start. First raise the car but not only front end couse some oil will stay in transferbox, if you need, then it is batter that rear end be higher then front.
    Locate drain and fill plug. PTO is located between front wheels behinde gearbox.
    ...
    It is ALEN 8mm key.

    IMPORTANT! First try to loosen fill plug!
    You can chack level at this point as note if there is leak (mine was 3-4mm lower then fill hole), then loosen and unscrew drain plug and catch oil. About 600ml will pour out.


    Let oil drain, and take time to clean both plugs. Drain is magnetic and will have some stuff on it, like grease. Fill one was covered with black like fine dust supstance in very thin leyer. Breake cleaner would come handy...
    ...

    Check drained oil (and measure ammount that come out, I had 600ml.)
    ...
    NEVER spill old oil in sewer. Collect it for recycling or give it at drop off point for used oil!

    Put drain plug back and tighten it. Seal is aluminium and cant be replaced, it comes with new plug. I reuse mine.

    You will need long hose with funel to pour from engine bay, or something like this:


    Pour new oil until it comes out from fill hole. Put fill plug back and tighten it. Seal is aluminium and cant be replaced, it comes with new plug. I reuse mine.
    Clean oil thet comes out on PTU, then clean it with brake cleaner for later inspection for leaks.

    Job done !
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