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Zafira A (1999-2005, petrol)
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  • Zafira
  • Zafira A
  • Transmission
  • Mechanical gearbox
  • Manual gearbox — technical condition check

Manual gearbox — technical condition check (Opel Zafira A)

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Before proceeding with the technical condition check, check the oil level in the gearbox (see "Gearbox - Checking the level and changing the oil"). In a gearbox that is operated with a low oil level in the crankcase, intensive wear of parts occurs and its failure is possible soon. On an inspection ditch or overpass, we inspect the gearbox from all sides, make sure there are no oil leaks.

1. From under the differential cover. If there are signs of leakage, the cover gasket must be replaced (see "Gearbox - Checking the level and changing the oil").

1. From under the differential cover. If there are signs of leakage, the cover gasket must be…


2. In places where the gearbox connects to the internal joints of the drives. The presence of traces of oil leaks in these places indicates the need to replace the front wheel drive seals (see "Front Wheel Drive Seals - Replacement").

2. In places where the gearbox connects to the internal joints of the drives. The presence of…


3. At the bottom of the joint between the clutch housing and the engine cylinder block. The presence of traces of oil leaks indicates the need to replace the gearbox primary shaft seal (see "Gearbox primary shaft seal - replacement") or the sealing ring of the clutch slave cylinder housing (see "Clutch slave cylinder - check and replacement").



3. At the bottom of the joint between the clutch housing and the engine cylinder block. The…


4. On the gearshift rod. If there are signs of leakage, the rod seal must be replaced (see "Gearshift mechanism rod seal").

4. On the gearshift rod. If there are signs of leakage, the rod seal must be replaced (see…


We make sure that the clutch release and gear shift mechanisms are in good working order and adjusted correctly. To do this, press the clutch pedal, engage all gears in turn, check the ease and clarity of their engagement and disengagement. If necessary, adjust the gear shift mechanism (see "Gearshift mechanism drive lever - replacement and adjustment").

Note: To troubleshoot the following problems: (if they are detected) the gearbox needs to be repaired, which involves disassembling it. This requires special equipment and high qualifications, so it is better to entrust the gearbox repair to a specialized Opel service.




We set the gearshift lever to neutral and start the engine. Press the clutch pedal several times and listen to the sound of the gearbox bearings. It appears when the clutch pedal is released and disappears when it is pressed. Loud noise from the bearings indicates that they are worn out and that the gearbox needs to be disassembled and repaired.

We check the operation of the gearbox while driving. We make sure that there is no crunching, knocking or other extraneous sounds when the gearbox is working. We check the operation of the synchronizers. To do this, moving first with acceleration, and then with deceleration, we shift gears up, then down. The gears should shift clearly and without crunching, and there should be no spontaneous disengagement of gears when the load changes.

Note: If a crunching sound is heard when shifting through all gears, the most likely cause is incomplete clutch disengagement (see "Clutch - checking technical condition").


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Previous articles
Opel Zafira A: Mechanical gearbox
Next articles

Manual transmission — reference data
Gearbox — Checking the level and changing the oil
Gearshift Drive — Removal, Repair and Installation
Gearshift mechanism drive lever — replacement and adjustment
Gearshift Rod Seal — Replacement
Front Wheel Drive Seals — Replacement
Gearbox — removal and installation


See similar ones from other Opel car manuals:
▶ Manual gearbox — repair, general information Opel Astra F (1991-1998, petrol)
▶ Removal, condition check and installation of the camshaft… Opel Corsa B (1993-2000)
▶ Cleaning and checking the technical condition of the… Opel Insignia A (2008-2017)
▶ Checking the technical condition of the oil pump Opel Kadett E (1984-1995)
▶ Manual gearbox — removal and installation Opel Omega A (1986-1993)
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Zafira A (1999-2005, petrol) 
  • General information
  • Governing bodies
  • User manual
  • Maintenance
  • Power unit
  • Engine repair
  • Control system
  • Cooling system
  • Exhaust system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Front wheel drives
  • Chassis
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  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Maintenance and care
  • Exterior
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  • Equipment and devices
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  • Electrical circuits
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