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Transmission Replacement - 1.4L LDD > < Selector and Gear Shift Lever Cable Bracket Replacement

Astra J

Transmission Replacement (1.3L Diesel LSF)

Special Tools

•  CH-904   Base Frame
•  DT-47648   Transmission Holder
•  EN-47649   Engine Support Fixture
•  CH-49290   Engine Support Tool

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove battery tray. Refer to Battery Tray Replacement .

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Note:  Do NOT disconnect engine coolant hoses.
2. Remove radiator surge tank clip (2).
3. Remove radiator surge tank (1) and lay aside.

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4. Remove shift lever and selector lever cable (2) from transmission control housing (3).
5. Remove shift lever and selector lever cable from shift lever and selector lever cable bracket (1).
6. Disconnect backup lamp switch electrical connector.

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Note:  Before disconnecting the clutch actuator cylinder front pipe, remove the clutch/brake fluid from the reservoir tank. Place basin underneath.
7. Disconnect clutch actuator cylinder front pipe (1).
8. Open retaining clip (arrow).

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9. Remove 2 upper transmission bolts (1).
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
11. Assemble the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
12. Support the CH-904   base frame on a jack.
13. Support the CH-49290   support tool on the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
14. Install the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
15. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .

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16. Remove the transmission front mount bolts (1) and the transmission front mount (2).

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17. Remove the transmission mount bracket - rear bolts (1) and the transmission mount bracket - rear (2).

Note:  In order to drain transmission fluid the clutch and differential housing cover must be removed.
18. Drain transmission fluid. Refer to Clutch and Differential Housing Cover Removal .
19. Install differential cover. Refer to Clutch and Differential Housing Cover Installation .
20. Disconnect left front wheel drive shaft from transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
21. Disconnect right front wheel drive shaft from transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
22. Lower vehicle.
23. Install the EN-47649   engine support fixture . Refer to Engine Support Fixture .

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24. Remove and DISCARD the transmission mount bolts - left side (1) from transmission mount bracket - left side.
25. Lower the engine and the transmission on the left hand side with the EN-47649   engine support fixture .

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26. Remove transmission mount bracket bolts - left side (1) from transmission (2).
27. Raise the vehicle.

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28. Remove 3 transmission lower bolts (2, 3, 4).

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29. Place DT-47648   transmission holder on CH-904   base frame and preinstall the supports as shown in the illustration.
30. Preinstall DT-47648-2   clutch housing support (4) to position 2 on the base plate.
31. Preinstall DT-47648-4   transmission housing support (2) to position 14 on the base plate.
32. Preinstall DT-47648-5 left   support with rear transmission swivel arm (1) to position A on the base plate.
33. Preinstall DT-47648-5 right   support with front transmission swivel arm (3) to position F on the base plate.

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Note:  Before placing in position slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports for the converter housing and transmission housing using the spindles until they are as low as possible.
34. Attach the DT-47648   transmission holder to the transmission.
35. Align DT-47648   transmission holder under transmission.
36. Attach swivel arms (1, 2) to transmission.

Note:  Align the swivel arms so that as little leverage as possible is created.
37. Tighten the bolt connections of the swivel arms, starting from the transmission and going as far as the base plate.
38. Position supports for clutch housing and transmission housing to transmission by twist up the spindles.
39. Tighten bolt connections of the supports.

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40. Remove last lower transmission bolt (1).
41. Separate the transmission from the engine.
42. Lower the transmission with the transmission jack and DT-47648   transmission holder far enough to remove the transmission.

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43. Remove transmission spacer (1) from engine.

Installation Procedure


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1. Install transmission spacer (1) to engine.
2. Raise the transmission with the transmission jack and DT-47648   transmission holder and position the transmission to the engine.

Caution: Refer to Fastener Caution .

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3. Install lower transmission bolt (1) and tighten to 60 N·m (44 lb ft) .
4. Remove the transmission jack with the DT-47648   transmission holder .

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5. Install 3 transmission lower bolts (3, 4) and tighten to 40 N·m (32 lb ft) .
6. Install transmission bolt (2) and tighten to 60 N·m (44 lb ft) .
7. Lower the vehicle.

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8. Install transmission mount bracket bolts - left side (1) to transmission (2) and tighten to 100 N·m (74 lb ft) .
9. Raise the engine and the transmission on the left hand side with the EN-47649   engine support fixture .

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10. Install the NEW transmission mount - left side bolts (1) but do not tighten yet.
11. Raise the vehicle.
12. Install the right front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
13. Install the left front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .

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14. Install the transmission mount bracket - rear (2) and tighten the bolts (1) to 100 N·m (74 lb ft) .

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15. Install the transmission front mount (2) and tighten the bolts (1) to 100 N·m (74 lb ft) .
16. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .
17. Lower the vehicle.
18. Remove the EN-47649   engine support fixture . Refer to Engine Support Fixture .

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19. Tighten the NEW transmission mount bolts left side (1) a first pass to 50 N·m (37 lb ft) .
20. Tighten the NEW transmission mount bolts left side (1) a final pass to 60 - 75 degrees , using the EN-45095   meter .
21. Raise the vehicle.

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22. Lower the CH-49290   support tool (1) with the CH-904   base frame and a jack.
23. Remove the CH-49290   support tool from the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
24. Disassemble the CH-49290   support tool (1) according to the details provided in the SPX installation manual.

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25. Install 2 upper transmission bolts (1) and tighten to 60 N·m (44 lb ft) .

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26. Connect clutch actuator cylinder front pipe (1) to clutch actuator cylinder pipe elbow.
27. Close retaining clip (arrow).
28. Connect the electrical connector to the backup lamp switch.

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29. Install shift lever and selector lever cable (2) to shift lever and selector lever cable bracket (1).
30. Install shift lever and selector lever cable to transmission control housing (3).
31. Adjust the shift lever and selector lever cables. Refer to Manual Transmission Shift Lever and Selector Lever Cable Adjustment .
32. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch System Bleeding .
33. Inspect the transmission fluid level. Refer to Transmission Fluid Level Inspection .

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34. Install radiator surge tank (1).
35. Install radiator surge tank clip (2).
36. Install the battery tray. Refer to Battery Tray Replacement .
37. Road test the vehicle.

Transmission Replacement - 1.4L LDD > < Selector and Gear Shift Lever Cable Bracket Replacement