Gearshift Drive — Removal, Repair and Installation (Opel Zafira A)

The operation must be performed during the removal of the gearbox, as well as if there is a need to replace the plastic bushings of the drive mechanism when they are worn out.

To perform the work you will need a snap ring plier (for drive repair).

Removal

1. Prepare the car for work (see "Preparing the car for maintenance and repair").

2. Shift into neutral.

3. Mark the relative position of the traction and the gear shift mechanism drive (if replacement of the drive lever is not planned) and using a TORX T50 key, unscrew the clamp tightening bolt.



4. Disconnect the rod from the drive.

5. Remove the spring clamp of the gear shift mechanism axle.



6. Remove the gear shift mechanism axle.





7. Disconnect the drive from the gear shift mechanism.



8. Using a slotted screwdriver, remove the retainer of the right fastening of the gear shift mechanism drive bracket.



9. Remove the left mount retainer in the same way.



10. Remove the gear shift drive assembly with the bracket.

Repair

Further operations are necessary to repair the gearshift drive. In this case, perform only those operations that are necessary to replace worn or damaged elements directly in your case. The malfunction of the elements is determined by the presence of mechanical damage and the presence of play in the connections of the gearshift drive levers.

1. To replace the gearshift drive rod, use a screwdriver to pry open the lock...



...and disconnect the rod from the ball joint.



2. Disconnect the second end of the rod in the same way.



3. If necessary, remove the rod sealing rings.



4. To replace the bushings of the drive rod levers and gear shift mechanism, use a puller to loosen and remove the retaining ring.



5. Remove the drive rod lever (we remove the gear shift lever in the same way).



6. Remove the plastic sleeve.



7. If necessary, remove the sealing ring.



8. If necessary, remove the protective element of the lever bushing.





9. To replace the intermediate lever bushing, use a file to grind down the flared part...



...and knock the axle out of the bracket.



10. Remove the gear shift mechanism drive from the bracket.



11. Pulling up...





...we remove the intermediate lever bushings.



12. Assemble in reverse order. Apply white lithium grease to the hinge joints.

Installation

We install the parts in the reverse order. When connecting the rod and the gearshift mechanism drive, we align the marks made during removal and tighten the clamp. If parts were replaced, it is necessary to adjust the gearshift mechanism drive lever (see below, "Gearshift mechanism drive lever - replacement and adjustment").