Note: A winch and hoist are required for this job.
Removing
1. Proceed as described in Chapter 7, paragraphs 1-18 inclusive.
2. Working in the engine compartment, remove the gear selection mechanism, as described in Sections 7A and 7B, depending on the model.
3. On manual transmission models, remove the retaining bracket, then pull the clutch cable off the release lever, if necessary, push the release lever back against the bulkhead so that the cable can be disengaged. On automatic transmission models, disconnect the shift cable from the control lever, then either unscrew the cable bracket or release the cable from the bracket. In any case, move the cable holder away from the bracket on the transmission housing, then move the cable and secure it to the side, taking into account the direction.
4. Disconnect the electrical wiring from the reversing light switch, which is located on the front side of the manual transmission housing, above the left mounting bracket. On automatic transmission models, disconnect the transmission wiring by disconnecting five connectors from various switches, coils and sensors. Release the electrical wiring from the brackets or other fasteners to the vehicle.
5. Where applicable, remove the automatic transmission breather hose from under the battery bracket. Disconnect the oxygen sensor harness, if used.
6. Unscrew the mounting sleeve, disconnect the speedometer drive cable from the transmission.
7. Turn off a fixing nut, disconnect a grounding strap from an end plate of transmission.
8. Make a final check that all relevant hoses, pipes, wires, etc. were disconnected and that they are not connected to the engine and transmission.
9. Proceed as described in Chapter 7, paragraphs 19 and 22.
10. Disconnect the inner ends of the driveshafts from the differential, referring to the appropriate points in Section 8. Be prepared for oil to leak when the driveshafts are disconnected from the differential, so plug the holes to prevent further oil loss and dirt ingress. Secure the drive shafts with wire or twine - do not let them hang under their own weight.
11. Attach the winch to the engine lifting brackets on the cylinder head, slightly raise the engine.
12. Remove the left transmission bracket by unscrewing the two bolts securing the rubber pad to the vehicle and body, the three bolts securing the mounting bracket to the transmission (see illustration).
13. Unscrew the right engine mounting bracket from the body and from the cylinder block, remove the mounting bracket.
14. Working under the vehicle, unscrew and remove the two nuts securing the rear engine/transmission mount to the lower frame and the three bolts securing the mounting bracket to the transmission, then remove the mounting bracket (see illustrations).
15. As needed, gently rock the engine/transmission assembly across the engine compartment to allow the assembly to come out vertically. Do not damage the components in the engine compartment.
Separation
16. After removing the engine/transmission assembly, place it on the bars placed in a workbench or on a clean area of the floor in the workshop.
17. Clean the assembly of dirt, use kerosene or water thinner and a stiff brush.
18. Unscrew and remove the protective cover of the transmission clutch housing.
19. Check that the engine and transmission are securely supported, then unscrew and remove the bolts securing the engine to the transmission.
20. Carefully disconnect the transmission from the engine. Take care that the transmission does not hang on the input shaft when it is connected to the clutch friction plate. Please note that the transmission is located on the pins placed in the cylinder block.
21. On models with automatic transmission, unscrew the protective cover of the clutch housing (three bolts), then, before unscrewing the torque converter, mark its position relative to the drive disk with chalk or a felt-tip pen.
Note: If the torque converter is removed from the transmission (even partially), there may be a significant fluid leak. To prevent this, disconnect the engine from the transmission and carefully support the torque converter by firmly pressing it against the transmission. If the transmission needs to be removed after some time, secure the torque converter by bolting a metal strip across the contact surface of the clutch housing. With a wrench on the crankshaft pulley/sprocket bolt, turn the crankshaft until the first bolt appears, then use a screwdriver or similar to pinch the teeth of the drive disc crown to prevent it from rotating when the bolt is removed. Loosen and remove the three screws one by one.
Compound
22. Before installing, check that the two bolts securing the left rubber transmission cushion to the vehicle body are freely screwed into their threaded holes. If necessary, update the thread with a M10x1.25 mm tap.
23. Where necessary, if the clutch assembly is removed from the flywheel, this is easier to install after the transmission has been installed.
24. On models with automatic transmission, if fluid has been spilled from the torque converter, be careful to fill it up to the maximum level possible. Wipe the transformer bushing to prevent damage to the transmission input shaft seal and check that the transformer is properly engaged with the pump shaft.
25. If the transmission has been replaced, clean the channels of the additional transmission fluid cooler. Opel recommends using low pressure compressed air, but great care must be taken not to distort the radiator.
26. Be very careful. All components must be absolutely clean, make sure that no dirt gets into the system.
27. Using an M10x1.25 tap, clean the threads in the torque converter holes, and prepare new bolts for assembly.
28. Tighten all nuts and bolts to the specified torque.
29. Be guided also Chapter 7, paragraphs 35 and 36.
30. Carefully connect the transmission to the engine (the clutch housing must rest on the pins in the cylinder block), then install and tighten the bolts securing the engine to the transmission with a tightening torque regulated specifications.
31. Install the protective cover of the transmission clutch housing.
Installation
32. Working under the vehicle, attach the rear bracket to the transmission. Use new stops under the bolt heads, and tighten the bolts to the specified torque.
33. Install the two bolts securing the engine/transmission rear bracket to the lower frame, but do not fully tighten at this stage.
34. Install the right engine mounting bracket to the cylinder block, tighten the mounting bolts with a tightening force regulated specifications.
35. Install the new right engine-to-body bracket bolts, but do not fully tighten them at this stage.
36. Install the left bracket to the transmission, tighten the fastening bolts with the tightening force regulated specifications.
37. Install new bolts of the left bracket for fastening the transmission to the body, and tighten them with a tightening torque regulated specifications.
38. Tighten the bolts of the right engine mounting bracket to the body and the bolts of the rear engine/transmission mounting bracket to the lower frame with a tightening torque regulated specifications then disconnect the hoist and winch from the engine
39. Clutch can now be installed where needed, the mission transmission input shaft should be engaged with the clutch friction disc hub (see Section 5).
40. Attach the inner ends of the drive shafts to the differential, following the appropriate points in Section 8, use new thrust washers.
41. Install the front exhaust system as described in Section 4C.
42. Install the crankshaft pulley by following the removal procedure in reverse order Chapter 7, item 22, and tighten the fastening bolts with a tightening torque regulated specifications.
43. On models with automatic transmission, connect wires to various switches, windings and sensors. Replace transmission saloon hose and oxygen sensor (if used).
44. Connect the transmission ground strap, tighten the mounting nut.
45. Lower the car to the ground.
46. Connect the speedometer drive cable to the transmission, clamp the fastening sleeve.
47. Connect the electrical wiring of the reversing lamp.
48. On manual transmission models, attach the clutch cable to the bracket on the transmission case, then connect the cable to the release lever, and adjust it as described in Section 6.
49. Install the gear selector. as described in Section 7A.
50. Proceed as described in Chapter 7, paragraphs 41-52 inclusive.
51. Top up the gear oil level as described in Sections 7A and 7B.
52. Finally, adjust the shift cable and fill the transmission with fluid (see above).
53. Connect the negative battery cable.
54. Next, go to Chapter 37.
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