Gearbox — removal and installation (Opel Astra G)

1. Raise the front of the vehicle and place it on stands. Remove the front wheels. Remove the lower engine guard, air filter and air ducts.

2. Drain the oil from the gearbox.

3. Remove the battery, battery tray and starter.

4. Disconnect the wire connectors from the gearbox. Remove the wiring from the brackets and clamps and move it to the side.

5. Clamp the hose, remove the clamp and disconnect the hose from the clutch slave cylinder nipple (see photo). Plug the holes.





6. Remove the front and intermediate exhaust pipes and the neutralizer

7. Disconnect the gear shift mechanism linkage from the gearbox.

8. Remove the axle shafts.

9. Raise the engine and remove the front subframe (Chapter 10).

10. Raise the gearbox using a jack dolly.



11. Loosen the bolts and remove the front support bracket from the clutch housing (see photo).



12. Unscrew the 6 mounting bolts and remove the gearbox suspension bracket from the left side of the crankcase (see photo). Lower the power unit so that the gearbox moves away from the mounts by approximately 50 mm, without allowing tension on the hoses and wires.



13. On a gearbox with a steel differential pan, unscrew the bolts and remove the lower cover of the clutch housing.

14. Unscrew the bolts securing the gearbox to the engine (when assembling, these bolts should be screwed in place).



15. Make sure that all necessary parts are disconnected and cannot interfere with the removal of the gearbox.



16. Carefully move the gearbox on the trolley and remove it from the guide pins. Roll out the trolley with the gearbox. Remove the guide pins.

17. Install the gearbox in reverse order. Once finished, adjust the gear shift mechanism.