The manual gearboxes used on the considered models of Opel Corsa/Tigra cars have a 5-speed design with full synchronization. The transmission number is stamped on top of the box crankcase.
The transmission case is cast aluminum alloy and is bolted to the left side of the engine. The manual transmission includes the actual gearbox and differential (main gear).
The torque developed by the engine through the friction disc of the clutch is transmitted to the splined pin of the manual transmission input shaft rotating in closed ball bearings. From the input shaft, rotation is transmitted to the output (secondary) shaft, the right pin of which is fixed in a roller bearing, and the left one in a closed ball bearing. From the output shaft, rotation is transmitted to the crown gear (driven gear) main gear and a differential assembly rigidly articulated with it, providing the ability to rotate the drive wheels at different angular speeds, which avoids excessive wear of the protectors during cornering.
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 gear position, the gears of the secondary shaft rotate freely on it, excluding the transmission of torque to the driven gear of the final drive.
Gear selection is carried out by means of a shift lever mounted on the floor of the vehicle interior and a gear selection mechanism. The linkage/cable of the gear selector force the shift forks to move, thereby providing displacement along the input shaft assembly of the synchronizer couplings in constant engagement with it. The introduction of the synchronizer clutch into engagement with the teeth of the corresponding gear on the output shaft causes the box to provide the required gear ratio corresponding to the selected gear. The design of brake rings, spring pins, gears and synchronizer sliding clutches provides the necessary smoothness and noiselessness for shifting. Synchronizing cones are formed by machined surfaces of brake rings and gears.
Due to the complexity of the design of the manual transmission, the lack of free sale of the necessary interchangeable internal components and the need to use special equipment, the compilers of this Guide do not recommend car owners to independently overhaul the gearbox. Repairing a box in a car service workshop is a rather expensive operation, and therefore, alternative options for replacing a failed unit with a new or refurbished one should be considered. Any useful information on the repair and replacement of the transmission can be obtained from Opel service stations. Regardless of the chosen troubleshooting method (repair or replacement), independent dismantling of the box from the car will significantly reduce material costs.
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