Astra H
Field Remedy: 2305
Remedy:In case of one or several customer complaints described above the shift fork for the 3rd/4th gear has to be replaced. If a tough gear shift is complained the following check has to be carried out before repair: - start engine - shift 1st gear - stop engine - disengage 1st gear and shift again If a tough gear shift occurs during this check the shift fork 3rd/4th gear is bent and has to be replaced. Note: The reinforced shift fork is available via P&A. Working procedure: 1. Remove transmission - see working procedure "Transmission, Remove and Install", group "K" of accordant Service Instruction. 2. Loosen transmission housing cover (picture I) - Unscrew 16x screw (arrows) 3. Remove transmission housing cover (picture II) - Loosen cover (1) with suitable tool (2,3) from transmission housing. Note: No beating or trashing onto the cover or the transmission housing. 4. Spray seal remover onto sealing area between cover and transmission housing and let it expose for about 15 min. Note: Use implicitly seal remover Loctite 7200 (order at your local Loctite retailer). 5. Remove reverse lamp switch (1, picture III). 6. Remove gear shift assembly (1, picture IV). - Shift transmission into neutral position - Unscrew 2x screw (2) 7. Remove control rod (1) of primary shaft (picture V) - Degrease control rod with silicone remover - Apply several layers of adhesive tape (2) onto control rod - Attach 1x cable strap (3) to avoid sliding - Grab control rod with pliers on the covered point and remove it upwards. Note: Implicitly avoid to damage the connecting rod. 8. Remove shift fork 3rd/4th gear (1) upwards (picture VI). 9. Clean 16x thread in transmission housing - Clean threads with final thread cutter und blow out with compressed air. Note: To avoid dirt contamination inside of the transmission the gear train has to be covered with a clean tissue. 10. Clean magnet (1) in transmission housing (picture VII). 11. Install new shift fork 3rd/4th gear into transmission. 12. Install control rod (1) of primary shaft (picture VIII) - Remove cable strap and adhesive tape from control rod - Clean control rod with silicone remover from adhesive rests - Assemble control rod carefully with plastic hammer. Note: Attend that shift forks (2) adjoin on the shifting sleeve during assembling. Avoid to cant the control rod. 13. Install gear shift assembly - Screw in 2x screw and tighten 21 Nm. 14. Install reverse lamp switch - Screw in switch and tighten 20 Nm. 15. Clean sealing area between cover and transmission housing - Remove seal remover and rests of sealing compound with a clean tissue from sealing area. 16. Apply sealing compound (1) uninterrupted with a thickness of 2-3 mm onto cover transmission housing (picture IX) Note: Use silicone sealing compound (part number 90543772 / catalogue number 15 03 298). 17. Install cover transmission housing (picture X) - Attach cover transmission housing without misalignment - Screw in 16x screw with hand. Note: Place in screw (16) implicitly in its original position. 18. Tighten 16x screw in two steps according to tightening sequence (picture X) - Step 1: 5 Nm - Step 2: 21 Nm - For verification tighten all screws clockwise with 21 Nm. 19. Carry out a functional check - Mount clutch plate - Shift each gear and rotate transmission at input shaft. 20. Install transmission - see working procedure "Transmission, Remove and Install", group "K" of accordant Service Instruction. Spare-Parts: Part-No.: Catalogue-No.: Reinforced shift fork 55570787 7 34 000 Seal remover Loctite 7200 Loctite retailer Silicone sealing compound 90543772 15 03 298 Transmission oil (1 litre) 9120541 19 40 768 Transmission oil (60 litre) 9194349 19 40 710 Transmission-oil drain bolt 93180976 7 02 929 Transmission-oil filler bolt 90446270 7 02 219 Labour Times: TC: Hours: Astra-H M32 / Z16LET U3 230 50 Replacement shift fork 90 5,6 Astra-H M32 / Z20LEH, Z20LEL, Z20LER U3 230 50 Replacement shift fork 90 5,4 Astra-H M20 / Z13DTH U3 230 50 Replacement shift fork 90 5,4 Astra-H M32 / Z17DTH U3 230 50 Replacement shift fork 90 6,6 Astra-H M32 / Z19DT, Z19DTL U3 230 50 Replacement shift fork 90 6,5 Astra-H M32 / Z19DTH U3 230 50 Replacement shift fork 90 6,4 Corsa-D M32 / Z16LER U3 230 50 Replacement shift fork 90 4,8 Corsa-D M20 / Z13DTH U3 230 50 Replacement shift fork 90 4,8 Meriva M32 / Z16LET U3 230 50 Replacement shift fork 90 4,8 Signum / Vectra-C M32 / Z22YH U3 230 50 Replacement shift fork 90 5,3 Signum / Vectra-C M32 / Z19DT, Z19DTL U3 230 50 Replacement shift fork 90 5,4 Zafira-B M32 / Z20LEH U3 230 50 Replacement shift fork 90 5,2 Zafira-B M32 / Z20LER U3 230 50 Replacement shift fork 90 5,1 Zafira-B M32 / Z22YH U3 230 50 Replacement shift fork 90 5,3 Zafira-B M32 / Z19DT, Z19DTH, Z19DTL U3 230 50 Replacement shift fork 90 6,1 The costs for this repair will be covered during the normal warranty. The regular warranty procedure should be used for claiming Set-up-time.
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