Removal and installation of automatic transmission (Opel Corsa C)

Removal

1. The gearbox can be removed in two ways: together with the engine on the subframe (see Chapter 2) or separately from the engine. In the second case, special lifting devices are required - a hoist, a winch or a special crossbar/rod, which is installed on top of the side members, and a set of rigging equipment. Opel service stations use a crossbar and a special universal kit for holding the engine in a suspended position (see Chapter 10).

2. Disconnect the battery (see Chapter 5), disconnect the electrical wiring from the engine control module (ECM) and remove it.

3. Disconnect the drive cable from the actuator lever and release it from the holder on the gearbox (see section 2). Disconnect the shift actuator lever wiring harness connector, release the wiring harness and move it aside.

4. Disconnect the upper oil hose from the AT, close the holes with suitable plugs.

Note: Depending on the configuration and layout of the units in the engine compartment, it may be necessary to separate and move aside some of the other lines running on top of the AT.

5. Remove the upper transmission-to-engine block mounting bolts and remove the ATF dipstick tube.

6. Lift the power unit using lifting equipment (see Chapter 10).

7. Install the right engine mount remover, remove the rear engine mount (see Chapter 2) and remove the front suspension subframe (see Chapter 10).

Note: The KM-6169 device must remain on the subframe - in this case it is intended for centering the AT during its subsequent installation.

8. Pry off the retainers with a suitable tool and disconnect the AT coolant system lines (see accompanying illustration). Close the holes with suitable plugs, remove traces of ATF leakage with a rag.



9. Remove the service covers (plugs) that close access to the torque converter mounting bolts and the hole for installing the KM-91 1 device (see illustration 5.8).

10. While turning the torque converter, unscrew the 3 bolts securing it to the drive disk one by one, holding the disk from turning using the KM-911 device, and disconnect the transformer from the disk.

11. Remove the drive shafts, including the intermediate shaft (with appropriate equipment) (see Chapter 8), while the shafts do not necessarily have to be removed completely - it is enough to disconnect them from the transmission and tie them to the supporting parts of the body on the bottom of the car.

Text was copied from the portal OpelBook.ru

12. Unscrew the mounting bolts and remove the left support of the power unit (see Chapter 2).



13. Gradually release the hoist/rigging equipment, lower the power unit by approximately 5 cm, - make sure that the communication lines laid underneath are not pinched (hoses and wiring) and make sure that nothing interferes with the removal of the box.

14. Disconnect the sensor wiring connector (see accompanying illustration) and install the MKM-886-A device on the box, lifting it with a jack.

Note: Before using the device, carefully read the instructions for use. Fix the box on the device.

15. Remove the lower transmission-to-oil pan mounting bolts, then the lower side bolts (see accompanying illustration) fastening the box to the engine, disconnect the box from the cylinder block, make sure that the transformer has separated from the drive disk, and lower it on the jack. Be careful - do not drop the torque converter and do not damage the transmission components.





16. Secure the torque converter using a special device (see accompanying illustration).

Installation

17. Installation is carried out in the reverse order of dismantling the components. Please note the following points:

• a) Before installation, run a tap through the threaded holes of the torque converter, completely removing traces of corrosion and old sealant from their threads (instead of a tap, you can use an old bolt of the appropriate size, after making a longitudinal cut in it);
• b) Make sure that the guide bushings are in place and lubricate the torque converter guide pin and the centering bushing on the crankshaft journal with molybdenum-containing grease (see accompanying illustration);
• c) Ensure that the transmission is installed correctly on the engine, tighten all fasteners to the required torque;
• d) Do not forget to replace the torque converter to drive plate mounting bolts;
• e) Replace the sealing rings of the ATF cooling system line nipples, check that the tubes are securely fastened;
• f) Be sure to replace the sealing element of the ATF dipstick guide tube;

18. Finally, fill the transmission with the required amount of fresh ATF (see Chapter 1 and Section 4 of this chapter) and adjust the gear shift drive (see Section 2).