Manual gearbox — removal and installation (Opel Omega A)

1. On carbureted models, remove the air filter as described in Section 3.

2. Place the car over the inspection pit. Apply the handbrake.

3. Loosen the driveshaft cam nut on the front of the driveshaft one full turn.

4. Unscrew the front exhaust distribution pipe from the intermediate part, the mounting bracket and the exhaust manifold. Also unscrew the mounting bracket from the gearbox.

5. Remove the bolts securing the front flexible drive shaft coupling to the gearbox output flange.

6. Move the cardan shaft back from the output flange, tie it on one side (photo).



7. Where applicable, remove the vibration damper from the output flange by turning it so that the special notches align with the ends of the flange (photo).





8. Disconnect the speedometer drive cable and tie it on one side.



9. Disconnect the wiring from the reverse light switch (photo).



10. Place a container under the gearbox, then use a socket wrench to loosen the drain plug and drain the oil (photo). Finally, replace the drain plug.



11. Measure the distance from the clutch cable lock nut to the end of the cable threads to ensure initial installation during assembly.

12. Loosen the lock nut and adjusting nut, remove the clutch cable from the release lever and clutch housing. Secure the cable to the side.

13. Unscrew the protective cover on the front side of the gearbox (photo).



14. Unscrew and remove the two lower bolts securing the gearbox to the engine.



15. Above the propeller shaft, disconnect the shift rod from the base of the shift lever. To do this, remove the spring clip from one end of the pivot pin and remove the pin (photo).





16. Remove the two bolts securing the gearshift lever hanger to the rear of the gearbox (photo).



17. To gain additional working space, unscrew and remove the bottom cross member located behind the gearbox.



18. Support the gearbox with a jack.

19. Unscrew the rear mount crossbar from the bottom.

[Material copied from this resource: OPELBOOK.ru]

20. Place a thin plate under the oil pan on the front crossmember (photo).



21. Lower the gearbox until the oil pan rests against the plate.

22. Unscrew and remove the remaining bolts securing the gearbox to the engine.

23. Slide the transmission rearward away from the engine, then remove it from underneath the vehicle. Be careful not to let the transmission hang on the input shaft.

24. If necessary, remove the spring clip, remove the pin and disconnect the gearshift rod from the gearshift lever shaft on the gearbox. Also unscrew and remove the crossmember and exhaust mounting bracket (photo).







25. Installation is carried out in the reverse order. Check that the release lever and bearing are correctly installed, lightly grease the grooves of the input shaft. To facilitate the entry of the input shaft and the grooves of the friction disc, select 4th gear and slowly turn the output flange. Note also that the friction disc must be centered as described in Section 5 for the gearbox input shaft to enter the crankshaft bushing bearing. Check and, if necessary, adjust the clutch cable. Tighten all nuts and bolts to the specified tightening torque Specification. Apply thread locking agent to the threads before inserting the crossmember bolts. Finally, fill the gearbox with the specified grade and amount of oil, tighten the filler plug (photo).