Release bearing and lever — removal and installation (Opel Vectra A)

Note: If the release bearing guide sleeve is removed, a new O-ring must be used during installation.

Removal

1. Access to the release bearing can be gained either by removing the clutch assembly as described in Chapter 5 (engine and transmission in the engine compartment), or by separating the engine from the transmission (the clutch assembly remains in place).

2. Loosen the clamp bolt securing the clutch release fork to the release lever pivot shaft.

3. If not already done, disconnect the clutch cable from the release lever by removing the clip from the threaded end rod and pulling the rod out of the lever.

4. Remove the release bearing from the guide sleeve, then remove the release lever pivot shaft from the clutch housing and remove the clutch release fork (see illustrations). If applicable, remove the bearing from the plastic ring.





5. Make sure the release bearing rotates smoothly.



While holding the outer ring of the bearing, try to move its inner ring in a horizontal plane.

If the bearing rotates unevenly or its rings are significantly displaced relative to each other, replace it.

The release bearing also needs to be replaced if a new clutch is installed.

6. If necessary, remove the release bearing guide sleeve by unscrewing the three mounting bolts. The input shaft oil seal can now be replaced. Remove the O-ring installed between the guide sleeve and the clutch housing. Remove the old oil seal from the guide sleeve using a screwdriver as a lever and install a new oil seal using a tubular drift or socket. Fill the space between the sealing lips of the oil seal with lithium grease, then install the guide sleeve using a new O-ring. The O-ring must be installed without grease (see illustrations).





7. If necessary, replace the plastic bushings that support the release lever pivot pin by knocking them out of the clutch housing with a drift. Insert the new bushings into place, making sure that their locking tabs fit into the corresponding grooves in the clutch housing (see illustration).

Installation

8. Installation of the release bearing and lever is carried out in the reverse order, paying attention to the following.

9. Lightly coat the inner surface of the release lever pivot bushings and the outer surface of the release bearing guide bushing with molybdenum grease.

10. Where applicable, install the release bearing into the plastic ring, then install the release bearing together with the release fork and tighten the release fork clamp bolt to the torque specified in Specifications (see illustration).



11. Install the clutch assembly as described in Chapter 5 or reconnect the engine and transmission as described in Sections 2A, 2B or 7A (depending on the model).

12. Finally, check the clutch cable adjustment as described in Chapter 3.