Removing
1. Remove the clutch.
2. Disconnect the clutch fork from the clutch release bearing and remove the bearing.
Disconnecting the clutch fork from the bearing
3. Pull the lever up out of the clutch basket.
4. Remove the clutch fork.
5. Disconnect the release bearing guide from the gearbox housing.
Disconnecting the bearing guide from the gearbox housing
6. Check the O-ring in the release bearing guide for dirt and damage and replace if necessary. To do this, use a screwdriver to remove the O-ring from the release bearing guide.
Examination
1. Squeeze the clutch release bearing and turn it at the same time. If the bearing makes noise, replace it with a new one.
Checking the clutch release bearing
The bearing is permanently lubricated. It does not need to be cleaned and re-lubricated.
2. Check sliding surfaces for wear, corrosion and damage.
Installation
1. Lubricate the new O-ring between the sealing lips with grease, e.g. OPEL-19 48 524 (90 001 825).
2. Press the O-ring on the press using the OPEL KM-445 special tool or a short piece of pipe of suitable diameter.
O-ring installation
3. Insert the rubber sealing ring into the groove on the manual transmission housing without lubricating the ring.
4. Install the release bearing guide on the manual transmission housing and secure it firmly 5 Nm.
5. Lubricate with a thin layer of lubricant (e.g. OPEL 19 48 524 or OPEL 90 001 825) release bearing sliding surfaces (clutch release bearing) along the guide bushing. If necessary, remove burnt grease residues.
Do not apply too much grease, so that it does not get on the friction surfaces of the clutch.
6. Install the clutch release lever.
7. Install the clutch release bearing on the guide sleeve and secure the clutch fork to the lever with force 35 Nm.
8. Install the clutch.
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