Field Remedy: 2021

Remedy:

Note: 
The TSB 2021 can only be used for transmissions up to 
transmission number: A 02058820 (04 February 2010). 

Note: 
Only M20-6/M32-6 speed transmission affected, 
not F40-6 speed transmission.

In case of customer complaint the transmission has to be checked as 
discribed below.
Install repair kit manual transmission if necessary.

Spare-Parts:                            Part-No.:      Catalogue-No.:

Seal remover Loctite 7200 
(order at your local Loctite retailer)

Note:
The usage of Loctite 7200 is mandatory.

                                       

Repair kit manual transmission          93189976       90 07 192
identification marks: 
NU, NS, J3, J4, J5, J8, 
J9, NR, C8, D4, H3, H4,
G9, F6, GK, YP, YQ, XA
YU, YA, YT, YH, YB, YD

Repair kit manual transmission          93189977       90 07 193
identification marks: 
C6, C7, D3, D5, D7, D8,
D9, E1, G7, G8, GJ, H1,
H2, YG, YE, YF, YL, YK
YN, YJ, YM

Transmission oil (1 liter)               9120541       19 40 768

Transmission oil (60 liter)              9194349       19 40 710

Locking compound                        90542117       15 10 181

Transmission oil drain bolt             93180976        7 02 929

Transmission oil filler bolt            90446270        7 02 219

Sealing compound                        90297970       15 03 167

Order repair kit manual transmission according to identification mark
on identification plate of transmission (position 1 in picture below).

Working Procedure:

 1. Remove transmission

    - see working procedure "Transmission, Remove and Install" ,
      group "K" according service literature.

 2. Loose transmission housing cover (Picture 1).

    - remove 16x screw

 3. Remove transmission housing cover (1) (Picture 2).

    - lift up constant with adequate tool (2) and (3)

    Note:
    No thumping or striking.

    Note:
    3rd and 4th gear are mounted on top of primary shaft 
    (1, Picture 3).

 4. Check gap clearance of 3rd gear.

    Note:
    2nd technician necessary.

    - engage 4th gear 
    - push synchronising disk in direction of 3rd gear
    - check gap clearance between synchronising disk 
      3rd gear (4, Picture 4) and gear wheel of 
      3rd gear (5, Picture 4)

 5. Check gap clearance of 4th gear.

    Note:
    2nd technician necessary.

    - engage 3rd gear 
    - push synchronising disk in direction of 4th gear
    - check gap clearance between synchronising disk 
      4th gear (3, Picture 4) and gear wheel of 
      4th gear (2, Picture 4)

    Important:
    Clearance between synchronising disk and gear wheel 
< 1 mm      (1, Picture 5)- synchronising disk worn out, repair necessary.     Clearance between synchronising disk and gear wheel >
= 1 mm 
    (1, Picture 4)- syncronising disk ok.

    Install the complete repair kit with synchronising disks 
    and gear wheels 3rd and 4th gear if one of both 
    synchronising disks is worn out.

    Measurement OK (Picture 4)

    Note:
    Picture 4 shows the measurement of clearance of 3rd gear.
    Act accordingly to measure the clearance of 4th gear.

    Measurement NOK (Picture 5)

    Important:
    Install the complete repair kit with synchronising disks 
    and gear wheels 3rd and 4th gear if one of both 
    synchronising disks is worn out.

 6. Remove reverse lamp switch (1, Picture 6).

 7. Remove gear shift assembly (1, Picture 7).

    - engage neutral gear
    - remove 2x screw (2)

 8. Remove control rod (1) of primary shaft (Picture 8).

    - degrease control rod
    - wrap adhesive tape (2) several times around control rod
    - attach cable strap (3) to prevent control rod from sliding 
      down
    - grab adhesive tape with gripper
    - strike out control rod vertical bottom-up

    Important:
    Do not damage control rod.

 9. Remove 2x selector fork (Picture 9).

    Note: 
    In case of any damages on the sliding shoes of the shift fork 
    3./4. gear (1)(Picture 9), use a new reinforced shift fork
    (Partnumber: 55570787 / Cataloguenumber: 7 34 000) when assembling 
    the transmission.

    - from reverse gear (2) and 3rd/4th gear (1)

10. Remove top primary shaft (1, Picture 10).

    - grab primary shaft at 3rd gear wheel and remove it 
      from transmission housing

11. Remove retaining ring of taper roller bearing (1, Picture 11).

    Important:
    Keep retaining ring. The thickness of the retainer ring must 
    be measured later.

12. Press-out taper roller bearing (2) (Picture 12).

    - prop at 4th gear wheel (3)

    Important:
    taper roller bearing must be re-used. 
    The transmission has to be replaced if the taper roller 
    bearing gets damaged.

    Note:
    Diameter of mandril (1) max. 24mm.

13. Remove needle bearing 4th gear (1) and synchronising disks (2)
    (Picture 13).

14. Remove retaining ring (1) from sleeve carrier (2) (Picture 14).

15. Press-off sleeve carrier (1, Picture 15).

    - apply pressure to gear wheel of 3rd gear (2)

16. Remove needle bearing 3rd gear (1, Picture 16).

17. Remove retaining ring of distance bush (1, Picture 17).

    Important:
    Do not damage bearing face of 3rd gear.

18. Press-off distance bush (1) (Picture 18).

    - use KM-6223-1 (3) and KM-6223-2 (2)

19. Align and press-on new distance bush (2) (Picture 19).

    - press on block with provided bushing (1)

20. Install new retaining ring (1, Picture 17).

21. Install new gear wheel 3rd gear (3) (Picture 20) 
    with needle bearing (see pos.1 in Picture 16).

    Note:
    Take care of needle bearing.

22. Install new synchronising disks (packet of 3) (2) (Picture 20).

    - spin gear wheel after pressing 

    Note:
    Observe alignment of synchronising disks:
    Place lugs (1) of gear wheel and synchronising 
    disk (1) congruent.

23. Mark and dissasemble new sleeve carrier with selector 
    sleeve (1) (Picture 21).

    Important:
    Sleeve carrier and selector sleeve must be installed later
    in the same setting.

24. Align and press-on new sleeve carrier (2) (Picture 22).

    - press on block with provided bushing (1)

    Note:
    Observe alignment of apertures (3) to synchronising disk.

25. Install new retainer ring (4) and new selector sleeve (3) 
    (Picture 23).

    Note:
    Regard mark (2).
    - place selector sleeve 
    - install 3x thrust piece (1) 
    - affix 3x thrust piece angular
    - press-in 3x thrust piece

26. Functional check 3rd gear.

    - spin gear wheel 3rd gear 
    Note:
    Test: fast spinning – slight backlash.
    A little resistance is normal.

27. Install and catch new synchronising disks (packet of 3) (1)
    (Picture 24).

    Note:
    Pay attention to aperture (2).

28. Install new needle bearing 4th gear (1, Picture 25).

29. Install new gear wheel 4th gear (1) (Picture 26).

    - engage lugs (2)

30. Functional check 4th gear.

    - spin gear wheel 4th gear

    Note:
    Test: fast spinning – slight backlash.
    A little resistance is normal.

31. Press-on old taper roller bearing (2) in correct
    position (Picture 27).

    - use provided bushing (1) 

32. Install new retainer ring (see position 1 in Picture 11).

    Important:
    The retaining rings have classified thicknesses.
    Measure thickness of old retaining ring in an area without
    burr. 
    Install new retainer ring out of provided set with identical 
    thickness.

33. Spray seal faces of transmission housing and 
    transmission housing cover with seal remover Loctite 7200.

    - Let seal remover permeate for 15 minutes

34. Clean magnet in transmission (1, Picture 28)

35. Clean 16x thread in transmission housing

    - cover gear wheels 
    - blow threads with compressed air after cleaning with 
      tapper

36. Insert primary shaft on top (see position 1 in Picture 10).

37. Insert 2x selector fork

    - reverse gear (2) and 3rd/4th gear (1)

    Note:
    See picture 9.

38. Install control rod (1, Picture 29)

    - remove adhesive tape and cable strap from control rod
    - assemble in control rod with plastic hammer

    Note:
    Assure that selector forks lie against selector sleeve 
    while assembling control rod.
    Avoid canting of control rod.

39. Install gear shift assembly (see position 1 in picture 7).

    - tighten 2x screw (2) with 21 Nm 

40. Install reverse lamp switch (see position 1 in picture 6).

    - tightening torque 20 Nm

41. Clean sealing  surface of transmission housing and 
    transmission housing cover.

    - wipe off seal remover with clean rag

42. Apply sealing compound Loctite 518 (1) to transmission 
    housing cover uninterrupted with 2-3 mm thickness 
    (Picture 30).

43. Mount transmission housing cover (see picture 1)

    Note:
    Tighten screws as shown in picture 1

    - tighten 16x screw
    - 1st step: 5 Nm
    - 2nd step: 21 Nm
    - check for correctness :
      retighten all screws clockwise with 21 Nm

    Note:
    Screw 16 has to be installed in its original position
    (see position 16 in picture 1)

44. Functional check before installation.

    - shift each gear and rotate transmission at input shaft
      , mount clutch plate.

45. Install transmission

    - see working procedure "Transmission, Remove and Install ",
      group "K" of according service literature.

Labour Times:                                  TC:            Hours:

    Note:
    All labour times are containing required time for removal and 
    installation of transmission and time for installation of repair 
    kit manual transmission.

Astra-H - Z 16 LET/M32

U3 202 10      Install repair kit              90             6.2
               manual transmission

Astra-H - Z 20 LEL, Z 20 LEH, Z 20 LER/M32

U3 202 10      Install repair kit              90             6.1  
               manual transmission             

                                               
Astra-H - Z 13 DTH/M20                         

U3 202 10      Install repair kit              90             6.1 
               manual transmission             

                                               
Astra-H - Z 17 DTH/M32                         

U3 202 10      Install repair kit              90             7.1
               manual transmission             

                                               
Astra-H - Z 19 DT, Z 19 DTL/M32                

U3 202 10      Install repair kit              90             7.1 
               manual transmission             

                                               
Astra-H - Z 19 DTH/M32                         

U3 202 10      Install repair kit              90             7.1 
               manual transmission             

                                               
Zafira-B - Z 20 LER, Z 20 LEH/M32              

U3 202 10      Install repair kit              90             5.8 
               manual transmission             

                                               
Zafira-B - Z 22 YH/M32                         

U3 202 10      Install repair kit              90             5.9
               manual transmission             

Zafira-B - Z19 DT, Z 19 DTL, Z 19 DTH/M32

U3 202 10      Install repair kit              90             6.7
               manual transmission             

                                               
Meriva - Z 16 LET/M32                          

U3 202 10      Install repair kit              90             5.4
               manual transmission             

                                               
Vectra-C/Signum - Z 22 YH/M32                  

U3 202 10      Install repair kit              90             5.9
               manual transmission             

                                               
Vectra-C/Signum - Z 19 DT, Z 19 DTL/M32        

U3 202 10      Install repair kit              90             6.1
               manual transmission             

                                               
Corsa-D - Z 16 LER/M32                         

U3 202 10      Install repair kit              90             5.4
               manual transmission             

                                               
Corsa-D - Z 13 DTH/M20                         

U3 202 10      Install repair kit              90             5.5
               manual transmission

The costs for this repair will be covered during the normal warranty.
The regular warranty procedure will apply.