Removal and installation the gearbox (F13) (Opel Corsa C)

Note: If the transmission is replaced, the items listed below must be replaced.

Clutch drive nipple.

Engine damper block bracket.

Shift cable bracket.

Rear gearbox bracket.

Removal

Remove the lower engine compartment cover, if equipped.

Remove the center muffler and front exhaust pipe.

Attach KM 6001-A to the front axle housing.

Loosen the 2 guide bolts (arrows) on the KM-6001-A.

Install KM-6001-A as shown in the figure.

Note: 2 journals must be in the holes of the front axle housing guide.

Tighten the 2 bolts for the adjustment tires.

Rotate the front support bearing until it contacts the guide pin of the front engine damper block.

Note: The guide pins must be located in the support bearings without clearance.

Rotate the rear support bearing until it contacts the guide pin of the rear engine damper block bracket.

Note: The guide pins must be located in the support bearings without clearance.

Remove the front axle housing.

Remove the air filter housing with the air intake hose.

Disconnect the wiring harness connector (4), reverse light switch.

Close the brake fluid reservoir.



Fill the brake system hydraulic fluid reservoir to the "MAX" mark.

Disconnect the discharge line with the fitting.

Note: Place a tray underneath to catch any brake fluid.

Unlock the retaining clamp with a screwdriver and disconnect it from the discharge line.

Bend the retaining clamp slightly and reinstall it onto the fitting.



Disconnect the left engine damper block.

Disconnect the damper block from the left bracket of the engine.

Unscrew the 3 mounting bolts.



Disconnect the top of the gearbox from the engine by unscrewing the 4 mounting bolts (arrows in the picture).

Note: If necessary, pull the cooling system pipe upward and secure it with cable ties.

Caution! Do not damage the wiring harnesses and fastening elements.

Lower the engine and gearbox approximately 5 cm using the special tool MKM-883-1.

Remove the wheel shafts from the gearbox.

Place a tray underneath to allow the transmission oil to drain.

Note: The wheel shafts remain in the wheel hubs.

Attach the wheel shafts to the underside of the vehicle.

Close the wheel shaft holes with plugs.



Disconnect the front engine damper block from the gearbox by unscrewing the 2 mounting bolts.

Disconnect the gearbox from the pan by unscrewing the 3 mounting bolts.

Disconnect the front and rear parts of the gearbox from the engine by unscrewing the 2 mounting bolts.

Caution! Do not damage the wiring harnesses and fastening elements.

Remove the gearbox.

Move the gearbox away from the engine block and carefully lower it.

Installation

Attach the gearbox to the engine.



Make sure the installation is correct.

Raise and center the transmission.

Attach the front and rear parts of the gearbox to the engine and tighten the 2 mounting bolts to 60 N·m.

Install the transmission pan and tighten the 3 mounting bolts to 40 Nm.

Attach the front engine damper block to the gearbox and tighten the 2 mounting bolts to 80 N·m.

Install the wheel shafts.

Raise the engine and gearbox using the special tool MKM-883-1.

Note: When installing the front axle housing, make sure that the support bearing KM-6001-A is properly positioned in the guide pin of the front engine damper block and the rear engine damper block bracket. If necessary, adjust the installation position of the engine and gearbox using the special tool MKM-883-1.

Install the front axle housing.

Note: Do not install the center muffler, front exhaust pipe, battery and battery support.

Install the air filter housing and air intake hose.

Install the left engine damper block.

Attach to the left support of the engine damper block and tighten the 3 mounting bolts to a torque of 55 N·m.

Attach the gearbox from above and tighten the 4 mounting bolts to 60 Nm.

Connect the discharge pipe with the fitting.

Note: The retaining clamp should snap into place.

Connect the reverse light switch wiring harness connector.

Disconnect the special tool KM-6001-A from the front axle housing.

Install the center muffler and front exhaust pipe.

Check the transmission fluid level.

Attach the lower engine compartment cover.

Note: Adjust the transmission shift rods if necessary.

Install the battery support.

Install the battery.

Program volatile memory.

Bleed the clutch hydraulic system.