Vauxhall Workshop Service and Repair Manuals

Transmission, Remove and Install (F13+/F17+ - Z16XEP, Z16XE1, Z16XER, A16XER, Z18XE, Z18XER, A18XER, Z17DTL)

Note:   If the transmission is replaced, the following parts must be transferred:

  Remove

4.   Disconnect wiring harness plug, reversing lamp switch (1) 5.   Detach clutch pressure hose (4) from connection piece (2) •   Open retaining clamp (3) •   Detach clutch pressure hose •   Close retaining clamp

6.   Detach gearshift rod (1) from gearbox cover (2) •   Press in retaining spring (arrow) of the hollow pin •   Lever out hollow pin with KM-569-A

7.   Z16XER, A16XER only: detach battery wiring harness (1) from bracket on transmission •   Open clip

8.   Release transmission at top •   Unscrew 4x bolt (arrows)

9.   Attach KM-6001-B to front axle body •   Release 2x bolt (arrows) for adjustment rails on KM-6001-B (1) •   Insert KM-6001-B as shown Note:   2x journals (2) and (5) must sit flush in the guide holes of the front axle body. •   Tighten 2x bolt for adjustment rails •   Twist up front support bearing (4) – as far as the stop on the guide pin of the front engine damping block Note:   The guide pins must sit in the support bearings with no play. •   Twist up rear support bearing (3) – as far as the stop on the guide pin of the rear engine damping block bracket Note:   The guide pins must sit in the support bearings with no play.

11.	Remove 2x axle shaft from transmission Note:   Axle shafts remain in the wheel hubs. •   Attach axle shafts to vehicle underbody. •   Seal 2x opening for 2x axle shaft with plug

12.   Detach transmission from left engine damping block •   Unscrew 3x bolt (1)

14.   Detach front engine damping block bracket •   Unscrew 2x bolt (1) 15.   Detach rear engine damping block bracket •   Unscrew 3x bolt (2)

16.   Place transmission holder DT-47648 on KM-904 and preinstall as shown in the illustration: Component Position on base plate Designation DT-47648-2 (4) 2 Clutch housing support DT-47648-3 (2) 14 Transmission housing support DT-47648-5 left (1) A Support with rear transmission swivel arm DT-47648-5 right (3) F Support with front transmission swivel arm

Important:   It is essential to follow the manufacturer's instructions for transmission holder DT-47648 . 17.   Attach transmission holder DT-47648 to transmission Note:   Before placing in position, slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports using the spindles until they are as low as possible. •   Place transmission holder DT-47648 with supports in position under the transmission •   Tighten bolt connections of the supports •   Attach swivel arm (1) and (2) to transmission •   Tighten bolt connections of the swivel arms starting from the transmission and going as far as the base plate Note:   Align the swivel arms so that as little leverage as possible is created.

18.   Detach transmission •   Unscrew 3x bolts (2), transmission to oil pan •   Unscrew 3x bolts (1) and (3), transmission to cylinder block Note:   Note differing bolt lengths •   Press transmission away from engine Important:   Do not damage attaching parts. •   Carefully lower the transmission with the hydraulic jack and extend the hydraulic jack

  Install

Important:   Ensure that no cables and brackets get trapped between the transmission and engine. 22.   Install transmission •   Insert wiring harness bracket with front bolt •   Tighten 3x bolts (1) and (3), transmission to cylinder block 60 Nm •   Tighten 3x bolts (2), transmission to oil pan 40 Nm

25.   Attach transmission to left hand engine damping block •   Screw in 3x bolt (1) Note:   Do not tighten bolts yet

26.   Attach front engine damping block bracket •   Tighten 2x bolt (1) 80 Nm 27.   Attach rear engine damping block bracket •   Tighten 3x bolt (2) 80 Nm

28.	Attach 2x axle shaft to transmission

30.   Attach transmission to left hand engine damping block •   Tighten 3x bolt (1) 55 Nm

32.   Fasten transmission at top •   Tighten 4x bolt (arrows) 60 Nm

33.   Attach gearshift rod (1) to gearbox cover (2) •   Insert new hollow pin (arrow) – Coat hollow pin with grease – Depress hollow pin until retaining spring engages

34.   Z16XER, A16XER only: attach battery wiring harness (1) to bracket on transmission •   Close clip

35.   Connect wiring harness plug for reversing lamp switch(1) 36.   Attach clutch pressure hose (3) to connection piece (2) Note:   The clutch pressure hose must audibly engage.

37.	Correct transmission fluid level

38.	Transmission Shift Linkage, Adjust

40.	Bleed hydraulic clutch actuation