Contents: Removal ⬇ Installation ⬇
Removal
The manual transmission should be removed when it is being replaced or repaired, but the engine does not need to be removed. It is not recommended to repair the manual transmission at home. Below we describe only the removal and installation of the power unit; this will require a special tool.
1. Disconnect the negative cable from the battery.
2. Using a screwdriver, remove the locking clip from the threaded portion of the clutch drive cable.
Retaining clip and connector for electrical wiring of D/W reverse lights
3. Use a crowbar to push back the clutch release lever and remove the clutch cable.
4. Disconnect the wiring of the D/W reverse lights (refer to illustration).
5. Disconnect the tachometer shaft (1). To do this, unscrew the locking screw from the manual transmission. Depending on the version, a frequency mileage sensor may be installed. In this case, it is necessary to disconnect the connector (2).
Tachometer shaft (1) and frequency sensor connector (2)
6. Mark the position of the left front wheel in relation to its hub so that the balanced wheel can be installed in its original position. Remove the wheel mounting bolts with the car on the ground. Jack up the front of the car, place it on stands and remove the front wheels.
7. Loosen the gearshift rod clamp mounting bolt and remove the rod.
Gear shift rod clamp mounting bolt
Material copied from this resource: www.opelbook.ru
8. Raise the engine slightly (see section Repair procedures for DOHC gasoline engines without removing them from the vehicle).
9. Remove the stabilizer bar with the suspension arm, ball joint and rod, (see Chapter Suspension and steering).
10. Disconnect the drive shafts from the manual transmission and tie them up with wire so that they do not interfere (see Chapter Suspension and steering).
When installing, replace the drive shaft sealing rings.
11. Remove the left front engine mount.
Left front engine mount
12. Unscrew the mounting bolts and remove the rear left manual transmission support.
13. Disconnect the ground cable from the bearing cap.
14. Lower the car a little.
15. Place a jack under the manual transmission.
16. Unscrew the mounting bolts (1) and remove the flywheel cover. Then unscrew the mounting bolts (2), press the manual transmission away from the engine and remove it downwards.
Flywheel cover mounting bolts (1) and gearbox to engine mounting (2)
When removing, be careful not to damage the primary shaft journal, gear shift lever joint, clutch release lever, reversing light D/W and tachometer drive.
Installation
1. Before installation, check the clutch (See Chapter Clutch and drive shafts).
2. Check the threads of the damper support holes on the left front frame holder. If necessary, carefully tap the threads with an M10x1.25 tap.
3. Raise the manual transmission and move it towards the engine.
4. Screw in the transmission mounting bolts to the engine and tighten them alternately with force 75 Nm.
5. Further installation is carried out in the reverse order of dismantling the components. Tighten the fasteners with the required force.
6. Check the oil level in the manual transmission (see Chapter Engines).
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