Removing
Note: See the warning given at the beginning Chapters 6.
1. Remove the transmission block (see related section).
2. Remove the release bearing from the cylinder, noting its location.
3. Wipe the outside of the squeeze cylinder, then loosen the union nut that secures the feed tube to the cylinder. Release the rubber o-ring from the transmission case and remove the tube assembly.
4. Loosen the union nut and release the bleeder tube from the release cylinder. If necessary, pull out the mounting bracket and remove the nipple assembly from the transmission case.
5. Remove the three mounting bolts and remove the release cylinder from the transmission input shaft. Remove the O-ring located at the rear of the release cylinder - it must be replaced. Take care not to get dirt into the transmission unit.
6. The release cylinder is a non-separable unit and must be replaced if it is defective. The only component that can be replaced separately is the input shaft seal (see related section).
7. Also check the release bearing. Make sure it turns smoothly and easily, without noise, and that its contact surface is smooth and free of cracks, pitting, and nicks. If there is any doubt about the condition of the bearing, replace it. Manufacturers recommend replacing the bearing, regardless of condition, every time the engine or transmission is removed.
Installation
8. If the old cylinder is installed, it is recommended to replace the input shaft seal regardless of its condition (see related section).
9. Clean and dry the contact surfaces of the release cylinder and transmission and install a new O-ring in the recess on the back of the cylinder.
10. Lubricate the release cylinder seal with a small amount of gear oil, then carefully place the cylinder on the input shaft and slide it into position. Make sure the O-ring is still properly seated in the groove, then install the release cylinder mounting bolts and tighten them to the specified tightening torque specifications.
11. Connect the bleeder tube to the release cylinder and tighten the union nut with a tightening torque specified specifications. Where necessary, attach the nipple assembly with a bracket.
12. Connect the feed tube to the release cylinder and install the O-ring into the transmission case. Make sure the tube is centered in the housing opening, then tighten the union nut to the specified torque.
13. Lubricate the inner bore of the release bearing with a small amount of high temperature grease (Opel recommends paste 1942 530). Carefully dose the lubricant so that its excess does not get on the lining of the clutch friction disc. Install the release bearing on the cylinder, orienting it as noted during removal.
14. Install the transmission unit (see related section).
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