Manual gearbox — disassembly into main blocks (Opel Omega A)

1. Clean the outside surface of the gearbox.

2. Remove the release bearing and lever as described in Section 5.

3. Unscrew and remove the reverse light switch (photo).



4. Unscrew the bolt, remove the speedometer drive gear and casing (photo).



5. Now it is necessary to remove the pin of the gearshift lever shaft lock, which is secured with a special cover. The GM tool for performing this operation is No. KM-630-1 and is used together with a hammer. If it is not possible to use this tool, a substitute can be made according to the dimensions shown in Figure 6.4. The grip must be welded, soldering will not be strong enough.

6. Use the cover removal tool, then remove the spring and retainer pin (photo).









7. Inside the clutch housing, unscrew the bolts and remove the clutch bearing guide sleeve above the input shaft (photo).



8. Use pliers to remove the internal retaining ring securing the input shaft bearing (photo).





9. Secure the output flange by bolting a piece of metal rod to it, then unscrew the flange nut using a 32.0 mm socket. Remove the flange with a suitable extractor (photo).





10. Unscrew and remove the reverse intermediate gear shaft mounting bolt (photo).



11. Remove the bolts securing the rear support housing to the main casing.



12. The input shaft must now be pressed through the bearing in the main housing to expose the rear bearing housing and pinions. A suitable tripod puller can be used to bolt the bearings to the main housing (photo).



13. Unscrew the bolts and remove the retainer plate from the rear support housing (photo).



14. Remove the retainer springs, then the ball retainers (photo).



15. Using a fine-tipped punch, push the cylindrical pins out of the gear shift forks, supporting the shafts with a block.



16. Note the position of the gear shift forks and shafts, make marks if necessary.

17. Pull out the drive shafts, disconnect the gear shift forks from the synchronizer bushings. Turn the gear shift lever shaft as necessary to move the selector finger to the side.

18. Unscrew the reverse intermediate gear shaft bolt. Pull the shaft out until the reverse intermediate gear comes out (photo). Remove the needle bearings.





19. Compress together the retaining ring securing the secondary shaft bearing in the rear support housing, and secure it in the compressed position using a bent piece of metal rod (photo).



20. The housing should now be heated to 100°C to remove the secondary shaft bearing and gears. It is recommended to use colored thermal pencils (photo) to ensure the correct temperature conditions are met.





21. When the required temperature is reached, carefully knock the secondary shaft out of the housing and remove the gearbox as an assembly (photo).



22. Separate the positioning mechanism from the input shaft and secondary shaft (photo).



23. Separate the input shaft from the secondary shaft (photo).