Removing and installing gearbox Opel Astra

The main malfunctions, for the elimination of which it is necessary to remove the manual transmission from the Opel Astra car, are as follows:

In addition, the gearbox is removed to replace the clutch, flywheel and rear engine crankshaft oil seal.

An automatic transmission is removed for almost the same reasons as a manual transmission, except for the need to replace the clutch and flywheel, which in this case are absent. Removal and installation techniques for manual and automatic transmissions are almost the same and are described using the example of a manual transmission. The difference lies in the design of the gearbox control drive.

Helpful Hints

The work of removing and installing the gearbox is very laborious, so be sure to first make sure that its malfunctions are not caused by other reasons (insufficient oil level, defects in the clutch drive, loosening of the gearbox, etc.).

The gearbox is quite heavy and its shape is not comfortable to hold, so we recommend removing the gearbox with an assistant.

You will need: keys "for 14", "for 19" and TORX E18, pliers (or welding pliers).

1. Remove the storage battery (see Removal and installation of the storage battery).

2. Remove the battery mounting shelf (see Removing and Installing the Battery Mounting Shelf).

3. Remove the front wheel drives (see Removing and installing front wheel drives).

4. Remove the starter).

5. Mark in any way (for example, with paint) the relative position of the rods and the tip of the gear lever in order to maintain the adjustment of the drive when reinstalling the box. Loosen the bolt of the terminal clamp of the gearshift control actuator, disconnect the rod and the tip of the gearshift lever.

6. Remove the retainer and disconnect the hose tip from the clutch release intermediate tube adapter.

7. Disconnect from the sensor of speed and the sensor of inclusion of a backing blocks of plaits of wires.

8. Disconnect pads of plaits of wires from arms of a transmission.

9. Straighten the cotter pin with pliers ...

10. ... remove the axle of the intermediate thrust of the gearbox control drive ...

11. ... and disconnect the rod from the gearshift mechanism.

12. Remove two spring clips for fastening the system of levers and control rods of the gearbox ...

13. ... and remove the system of levers and rods from the gearbox brackets.

14. Attach the hoist straps to the front and rear transport eyes of the power package and tighten the straps.

15. Remove the front subframe (see Removal and installation of the front subframe).

16. Remove the bolts securing the clutch housing to the engine block (for clarity, the photo was taken on the removed power unit).

17. Turn out two bolts of fastening of the pallet of an oil crankcase to a crankcase of coupling.

18. Establish a support under a transmission case.

19. Move the gearbox as far back as possible (the input shaft should disengage from the hub of the clutch disc), remove the support from under it and remove the box from your Opel Astra.

Warning

When removing the gearbox, do not rest the end of the input shaft on the petals of the diaphragm spring, so as not to deform them.

20. Establish a transmission and all removed details and knots in an order, the return to removal.

Helpful Hints

Before installing the gearbox, we recommend lubricating the splines of the input shaft

thin layer of refractory grease.

Check with a special mandrel how the clutch disc is centered (see Removing and installing the clutch).

Before attaching the front wheel drives to the gearbox, replace the retaining rings on the splined shank of the inner joints with new ones. Otherwise, there is a possibility of disconnection of the drives from the gearbox while driving.

21. Fill the transmission with oil (see Checking the level, topping up and changing the oil in a manual transmission and the working fluid in an automatic transmission).

22. If necessary, adjust the gear change drive (see Adjusting the gearbox control drive).

23. Pour working fluid into the master cylinder reservoir (into its section designed to power the clutch release hydraulic drive) and bleed the clutch release hydraulic drive (see Bleeding the Clutch Release Hydraulic Drive).

Source http://www.automnl.com/model/opel_astra_h2/336/