Transmission — removal and installation (Opel Omega B2)

Removal

1. Disconnect the negative cable from the battery.

Note: On models with Opel Anti-Theft Warning System (ATWS), the negative battery cable must be removed within 15 seconds after turning off the ignition to prevent the hazard warning lights from activating.

2. Block the rear wheels, then apply the handbrake. Jack up the front of the car and support it securely on axle stands. Remove the mounting bolts and remove the lower engine/transmission cover.

3. Route the hydraulic line/clutch hose from the transmission unit to the nipple in the engine compartment bulkhead. To minimize fluid loss, pinch the feed hose connecting the reservoir to the clutch master cylinder, then release the nipple from the bulkhead. Pull the clamp off and separate the halves of the tube. Plug the ends of the tube to minimize fluid loss and prevent dirt from entering. Install the retaining clamp in the groove of the nipple, then ensure that the lower end of the tube is free and can be removed with the transmission unit.

Caution: Do not press the clutch pedal while the hose is disconnected.

4. Disconnect the wiring connector from the reverse light switch located at the rear of the transmission unit.

5. See. Section 8 and detach the front end of the propeller shaft from the transmission flange, then remove the vibration damper (where is available). Move the cardan shaft away from the transmission unit to the right and tie it to the bottom of the car.

6. Remove the gear shift rod as described in Chapter 4.

4-cylinder engines

7. On engines with a single overhead camshaft (SOHC), disconnect the wiring connector from the ignition control module. Loosen and remove the module bracket mounting bolts, marking the location of the engine mounting eye, then remove the electrical wiring and remove the module and bracket from the rear of the cylinder head. Release the high-voltage wires from the mounting brackets and move the assembly away from the transmission unit.

8. On all models, disconnect the oxygen sensor wiring connector from the transmission module and unplug it.

9. Loosen and remove the bolts securing the front section bracket of the exhaust system and remove the bracket. Also remove the bolts securing the front section to the intermediate section and separate the sections from each other.

10. On models with a one-piece oil pan, loosen and remove the bolts securing the brackets to the transmission case and the cylinder block walls. Remove both brackets from the engine, then remove the lower flywheel cover from the base of the transmission case.

11. On all models, loosen and remove the two bolts securing the upper bracket to the rear of the transmission unit.

12. Support the transmission with a jack, placing a piece of wood between them, and raise the jack to support the weight of the transmission.

13. Loosen and remove the bolts securing the rear transmission mount crossmember to the vehicle body.

14. Lower the transmission assembly slightly, then loosen and remove all bolts securing the transmission case to the engine. Note the location of each bolt and bracket to aid in subsequent installation. Again, ensure that all components are separated and clear of the transmission and that they do not interfere with removal.



15. Move the jack and transmission rearward to remove the block from the locating pins, then lower the jack and slide the block out from under the vehicle. Remove the locating pins from the transmission or engine if they are loose and store them away from the work area.

16. Remove the release bearing from the release cylinder and inspect it for signs of wear. Make sure it rotates smoothly and easily, without noise, and that its contact surface is smooth, free of cracks, pitting, and scoring. If there is any doubt about the condition of the bearing, replace it.

6-cylinder engines

17. Remove both front sections of the exhaust system (see the relevant section).

18. Remove the transmission unit as described in steps 11-16.

Installation

19. Perform installation in reverse order, paying attention to the following:

• a) Clean all dirt and grease from the input shaft grooves and the contact surfaces of the release bearing and release cylinder. Lubricate the inner bore of the release bearing with a small amount of high-temperature grease (Opel recommends using paste 19 42 530) and apply a little of the same grease to the input shaft grooves. Do not overdose the paste, otherwise its excess will contaminate the clutch friction disc linings. Install the release bearing on the cylinder, orienting it correctly.
• b) Place the dowel pins back in place. Install the transmission unit. Be very careful not to let the transmission hang on the input shaft by its own weight.
• c) Remove all traces of blocking compound from the threads of the bolts that secure the rear transmission suspension crossmember to the body. Apply a few drops of fresh compound (Opel recommends using 15 10 181) onto the threads of each bolt, install them and tighten them to the tightening torque specified in the Specifications.
• d) Tighten all nuts and bolts to the specified tightening torque Specifications (where given).
• d) Check the condition of the clutch hydraulic pipe nipple O-ring and secure the pipe/hose end with clamps in the operating position. Remove the clamp from the master cylinder hose and bleed the clutch hydraulic system as described in Section 6.
• e) Finally, check and, if necessary, top up the transmission oil level (see Chapter 2). If necessary, adjust the gear shift rod as described in Chapter 3.