Removal and installation the gearbox (Opel Kadett E)

Removal

Note: Removal and installation of the gearbox shafts, as well as disassembly and assembly of the differential, can be performed without removing the gearbox. Before removing the shafts, it is necessary to extend the input shaft of the gearbox as far as it will go, as described in the section "Clutch", and remove the rear cover of the gearbox.

Disconnect the clutch cable from the clutch release fork lever.

Loosen the bolt securing the gearshift rod clamp.

Disconnect the flexible speedometer drive shaft from the gearbox.

Disconnect the wire from the reverse light switch (if it is installed).

Loosen the three lower bolts securing the clutch housing to the engine block.

Disconnect the ground wire from the side member, lift the car and remove the front wheels.

Loosen the nuts of the ball joint pins of the front suspension arms and press the ball joints of the arms out of the steering knuckles, which are made integral with the front suspension strut.

Press the front wheel drive shafts out of the differential outlets.

Remove the front wheel drive shafts from the differential axle gears and immediately close the holes in the differential with plugs.

Unscrew the plug from the rear cover of the gearbox. Mark the position of the primary shaft of the gearbox relative to its gear block.



Remove the retaining ring and remove the cylinder bolt from the rear end of the transmission input shaft.





Using the Kukko 22-1 puller and the KM 449-1 device, move the primary shaft until it stops so as to remove the splines of the primary shaft from the splines of the clutch driven disk hub.

Support the engine and remove the left front powertrain mount bracket.

Remove the rear powertrain suspension bracket.

Remove the muffler inlet pipe mounting bracket from the gearbox.

Place a hydraulic jack under the gearbox, unscrew the upper bolts securing the clutch housing to the block and remove the gearbox.

Installation

Install the gearbox onto the engine block and tighten the mounting bolts.

Install the rear suspension bracket first, then the front powertrain suspension bracket. Apply locking compound to the threads of the bracket mounting bolts and tighten the bolts to the required torque.

Lubricate the differential box bearings with transmission oil, install new retaining rings on the wheel drive shafts and insert the shafts into the axle gears using a screwdriver until the retaining rings snap into place.

Move the primary shaft by hand until its splines engage the splines of the clutch driven disk hub. Using the KM 564 device, tighten the cylindrical bolt to seat the primary shaft. Install a new retaining ring, lubricate the plug threads with sealant and screw it into the rear cover of the gearbox. The plug should protrude above the crankcase plane no more than 4 mm.



Attach the ball joints of the front suspension arms to the steering knuckles, tighten the new ball joint nuts and lock them with new pins.

Install the wheels, connect the wire to the reverse light switch, connect the clutch cable and the ground wire.

Connect the flexible speedometer drive shaft to the gearbox.

Adjust the gear shift drive as follows.

Check the oil level in the gearbox housing and top it up to normal if necessary.