Removal and installation of manual transmission (Opel Vectra C)

1. The gearbox can be removed in two ways: together with the engine on the subframe (see Chapter 2) or separately from the engine. In the second case, special lifting devices are required - a hoist, a winch or a special crossbar/rod, which is installed on top of the side members, and a set of rigging equipment. Opel service stations use a crossbar and a special universal kit for holding the engine in a suspended position.

2. Remove the battery with the tray (see Chapter 5). On some models it may be necessary to remove the engine cover (see Chapter 2) and expansion tank.

3. Remove the retaining ring (see accompanying illustration) union on the hydraulic line coupling and disconnect the clutch hose. Carefully squeeze the lock and place the retaining ring in its place in the connector. The sealing ring must be replaced without fail. Immediately plug the open ends of the tube and hose to minimize hydraulic fluid loss and prevent dirt from entering the system.

Caution: Do not squeeze the clutch pedal when the hose is disconnected!

4. Disconnect the wiring from the sensor switch (see illustration 11.3) reverse lights and release it from the intermediate fasteners on the gearbox housing.

Note: Depending on the configuration and type of the manual transmission, other electrical wiring lines may be connected to it or laid along it - they must also be disconnected.

5. Disconnect the cable ends (see illustration 11.3) from the gear shift mechanism, remove them from the support brackets and move them to the side. If necessary, remove the cable bracket.

6. Remove the 3 upper transmission-to-engine mounting bolts (see accompanying illustration).

Note: The location of both the upper and lower transmission mounting bolts may vary slightly between models.

7. Lift the power unit using lifting equipment (see Chapter 10).

8. Secure the radiator and remove the front bumper cover.

9. Remove the exhaust system (see Chapter 4).

10. Install the right engine mount remover (see Chapter 2, Section 5) and remove the front suspension subframe (see Chapter 10).

Note: The device must remain on the subframe - in this case it is intended for centering the manual transmission during its subsequent installation.

11. Remove the drive shafts, including the intermediate shaft (with appropriate equipment) (see Chapter 8).

12. Unscrew the mounting bolts and remove the left support of the power unit (see Chapter 2).

Note: On some models it may be necessary to remove the support mounting bracket as well.

13. Remove the mounting bolts and separate the front support and the rear support bracket of the powertrain suspension from the clutch dome.

14. Gradually release the hoist and lower the power unit by approximately 5 cm, making sure that the communication lines laid underneath are not pinched (hoses and wiring) and make sure that nothing interferes with the removal of the box.

15. Unscrew the lower bolts securing the gearbox to the oil pan and install the MKM-886-A device on the gearbox (see accompanying illustration), lifting it on a jack. Secure the box to the device.

Note: Before using the device, carefully read the instructions for use.

16. Remove the lower side bolts (see illustration 11.15) fastening the box to the engine, disconnect the box from the cylinder block and carefully lower it on the jack.

17. If you don't have a special device, use one or two assistants - unbolt the clutch dome from the engine block, move the gearbox and lower it by hand. Be careful, drain the transmission oil if necessary.

18. Installation is performed in the reverse order of removal. Do not forget to bleed the clutch drive and adjust the gear shift drive (see Section 8), and also check the transmission oil level (see Chapter 1 and Section 4).