General information about manual transmission (Opel Corsa B)

The manual transmissions used in the Opel Corsa/Tigra models under consideration have a 5-speed design with full synchronization. The transmission number is stamped on the top of the gearbox housing.

The transmission housing is cast from aluminum alloy and is bolted to the left side of the engine. The manual transmission includes the gearbox itself and the differential (main gear).

The torque developed by the engine is transmitted through the friction disk of the clutch to the splined journal of the primary shaft of the manual transmission rotating in closed ball bearings. From the primary shaft, rotation is transmitted to the output (secondary) shaft, the right journal of which is fixed in a roller bearing, and the left - in a closed ball bearing. From the output shaft, rotation is transmitted to the crown gear (driven gear) the main transmission and a differential assembly rigidly connected to it, which allows the drive wheels to rotate at different angular speeds, which avoids excessive wear of the treads when turning.

The primary and secondary shafts of the manual transmission are located parallel to the axes of the crankshaft and drive shafts in such a way that their teeth are in constant engagement. In the neutral position, the secondary shaft gears rotate freely on it, excluding the transmission of torque to the driven gear of the main gear.

Gear selection is performed by means of a shift lever mounted on the floor of the vehicle interior and a gear selection mechanism. The gear selection mechanism rods/cable cause the shift forks to move, thereby ensuring the displacement of the synchronizer clutches in constant engagement along the primary shaft assembly. Engaging the synchronizer clutch with the teeth of the corresponding gear on the secondary shaft causes the gearbox to provide the required gear ratio corresponding to the selected gear. The design of the synchronizers, consisting of brake rings, spring-loaded pins, gear transmissions and sliding clutches, ensures the required smoothness and noiselessness of the shifts. The synchronizing cones are formed by the machined surfaces of the brake rings and gears.

Due to the complexity of the design of the manual transmission, the lack of commercially available replacement internal components and the need to use special equipment, the authors of this Guide do not recommend that car owners perform major repairs to the gearbox themselves. Repairing the gearbox in a car service workshop is a fairly expensive operation, and therefore, alternative options for replacing the failed unit with a new or refurbished one should be considered. Any useful information on repairing and replacing the transmission can be obtained at Opel service stations. Regardless of the chosen method of troubleshooting (repair or replacement), independent dismantling of the box from the car will significantly reduce material costs.