Attention! A new main pan gasket will be required. If the intermediate pan must also be removed, purchase a new gasket for it as well.
1. The transmission does not have a drain hole. If for any reason the transmission fluid needs to be drained, the main sump must be removed, and in some cases the intermediate sump as well.
2. Park your car on level ground (not slanted), turn off the ignition and apply the handbrake. To improve access, jack up the front of the vehicle and place it securely on axle stands. Please note that when filling the block and measuring the liquid level, the car must be in a horizontal position.
3. Place a container under the fluid level plug on the right side of the main transmission pan. Unscrew the plug and remove it together with the sealing washer (see illustration).
4. Let the liquid drain into the container, then install the stopper (see illustration).
5. Keep in mind that the pan is still filled with oil, place a large container under it. Loosen and remove the sump bolts evenly and gradually, noting the location of the refrigerant tube mounting brackets (see illustration). Carefully remove the drip tray and pour the contents into the container. Remove the gasket - it must be replaced.
6. To completely drain the fluid from the transmission unit, loosen and remove the intermediate pan mounting bolts, and then remove it from the transmission and drain the contents into a container. Remove the gasket - it must be replaced.
7. Remove the three mounting bolts and remove the transmission fluid filter (see illustrations). Wash the filter element in solvent, then inspect it for clogging and damage. If the filter element is clogged or its seal is damaged, the filter must be replaced (seal not sold separately).
8. Clean the contact surfaces of the sump and transmission and wipe the inside. Remove the magnet from the main tray and remove all metal particles from it.
Particles should be very fine - large metal chips indicate wear on transmission components (see illustration). Also remove all traces of blocking compound from the threads of the pan bolts.
9. Make sure the filter and transmission contact surfaces are clean and dry. Place the filter in the transmission, then install the mounting bolts and tighten them with the tightening torque specified specifications.
10. Where necessary, install intermediate pan with new gasket (see illustration). Apply some blocking compound (Opel recommends compound 15 10 181) on each of the mounting bolts, then install the bolts and tighten them evenly and gradually with a tightening torque regulated specifications.
11. Make sure the mating surfaces of the main pan and transmission unit are clean and dry. Install a new gasket on the pan and apply some blocking compound (Opel recommends using 15 10 181) for each mounting bolt. Install the pan and gasket, then insert the bolts and tighten them evenly and gradually with the tightening torque specified specifications (see illustration).
12. Filling the transmission is very inconvenient. Make sure the vehicle is level, then fill the transmission by slowly pouring in fresh fluid through the plug hole in the main pan. Once the fluid level reaches the bottom of the plug opening, start the engine.
13. Let the engine idle and carefully pour in the rest of the liquid. As soon as the liquid level reaches the base of the plug hole again, install the plug and sealing washer and tighten it with the tightening torque specified specifications.
14. Drive a short drive so that the new fluid is completely distributed around the transmission components, then recheck the fluid level (see related section). When finished, install a new sealing washer on the level plug, then install the plug and tighten it with the specified tightening torque specifications.
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