The gear shift mechanism requires adjustment if individual gears do not engage, the selected gear "jumps off" when the clutch is engaged, or if its components have been replaced. All gears should be easy to engage both when the vehicle is stationary and when the engine is running and the clutch pedal is depressed.
Components of the gear shift mechanism
1. Set the manual transmission to neutral. Jack up the car and place it on supports.
2. Remove the gear shift lever rod mounting bolt.
Retaining clip and connector for electrical wiring of D/W reverse lights
3. Unscrew the plug from the adjustment hole of the manual transmission gear shift mechanism cover.
Adjustment hole plug
4. Turn the rod to the left so that the OPEL-KM-527-A tool can be inserted into the adjustment hole until it stops. A 5 mm drill can be inserted instead of the specified tool.
On vehicles produced since 09.1995, there is a pin with a spring in the indicated location. Ask an assistant to press and hold the indicated pin.
5. Detach the gear shift lever boot and fold it upward.
6. Move the gear shift lever in neutral to the left so that the holes in the gear shift lever plate and in the gear shift lever housing are aligned.
7. In this position, tighten the clamp with force 15 Nm.
8. Remove the KM-527-A tool and close the adjustment hole with a new plug.
9. Lower the gear shift boot and secure it.
10. Lower the car to the ground.
11. Engage all gears in turn; if you experience any difficulties, repeat the adjustment.
12. Drive the vehicle and check the ease of gear shifting and repeat the adjustment if necessary.
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