Contents: Removal ⬇ Installation ⬇
Removal
Disconnect the ground wire from the battery.
Loosen the gearshift rod mounting clamp (see arrow in fig.).
Engage 2nd or 4th gear and disconnect the rod.
Remove the clamp on the end of the clutch cable with a screwdriver (see fig.C0028).
Use a crowbar to push the clutch release lever back and remove the clutch cable rod.
Disconnect the connector from the reverse light switch.
Loosen the speedometer cable mounting bolt. Loosen the gearbox mounting bolts and remove the speedometer drive. In vehicles equipped with the Motronic fuel injection system, disconnect the connector from the electric speedometer (see fig.).
Secure the engine on a special Opel KM-263 lift. If there is no lift, hang the engine on a section of pipe, resting it on the body fenders. Caution! Place wooden pads under the pipe to avoid damaging the fenders.
Loosen the front wheel mounting bolts.
Mark the position of the wheel disc relative to the wheel hub with chalk.
Raise the vehicle and place it on supports.
Remove the front wheels.
Remove the exhaust pipe.
Remove the front suspension strut.
Disconnect the axle shafts from the gearbox.
Attention! When removing the axle shaft, oil will leak out, so it is necessary to immediately close all openings. Hang the axle shafts on a wire. When installing the axle shaft, replace the seal.
Loosen the front left engine mount bracket mounting bolts (see fig.D0153).
Disconnect the ground wire from the battery.
Lower the car.
Lower the engine by 5 cm. The clutch release lever should be below the level of the longitudinal beam of the body.
Place the vehicle on supports.
Remove the gearbox input shaft from the clutch housing.
Support the gearbox with a hydraulic jack. If you have the Opel KM-V device and a lift, the gearbox can be secured to the device and lifted using the lift. To do this, install the Opel KM-444-V device on the gearbox and secure it with three locking bolts (see fig.).
Loosen bolts A securing the gearbox cover (see fig.).
Loosen the bolts B securing the gearbox to the engine.
Press the gearbox away from the cylinder block and remove it downwards.
Caution! Place the gearbox carefully. Do not rest it on the input shaft, gear shift rods, clutch release lever, reversing light switch or speedometer drive.
Original posted on the website (opelbook.ru)
Installation
Before installing the gearbox, check the clutch.
Check the thread for installing the shock absorber on the left front beam. If necessary, carefully clean the thread with a tap M10x1.25.
Raise the gearbox and install it on the cylinder block.
Alternately tighten the gearbox mounting bolts to a torque of 75 Nm.
Tighten the housing cover mounting bolts to 7 Nm.
Install the clutch and insert the primary shaft of the gearbox. To do this, lift the gearbox, providing access for the Opel K-564 device.
Tighten the ground wire mounting bolt.
In engines with a power of 150 hp, pay special attention to the fact that the ground wire does not rub against the plastic covering of the engine compartment. If the engine is started with the wire not connected, the computer may fail.
Tighten the bolts securing the left front engine mount shock absorber to the gearbox to a torque of 65 Nm.
Tighten the bolts to the left longitudinal beam of the front suspension to a torque of 75 Nm. Use only new bolts. Align the gearbox with a hydraulic jack.
Install the axle shafts.
Install the front suspension beam.
Install the engagement sleeve onto the gearshift lever splines. Adjust the sleeve position later.
Install the exhaust pipe.
Tighten the front wheel mounting bolts.
Lower the car.
Remove the jack to lift the engine.
Tighten the upper gearbox-to-engine mounting bolts to 75 Nm.
Connect the reversing light connector to the gearbox.
Install the speedometer shaft to the gearbox and tighten its mounting bolt (in vehicles with Motronic fuel injection system, connect the connector).
Connect the clutch cable.
Tighten the wheel mounting bolts crosswise.
Check the oil level in the gearbox.
Adjust the gearbox control drive.
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