Vauxhall Workshop Service and Repair Manuals

Disconnect battery. Raise vehicle.

  Remove

Drain transmission fluid at checking screw of transmission fluid pan of main housing. Unscrew propshaft from output flange (3 screws, 3 nuts). Push propshaft together and suspend from underbody.

Install hydraulic jack and adapter No. 09 00 094 with mounting plate F 09 18 021. Unscrew transmission crossmember from vehicle underbody (1).

Unscrew transmission crossmember (2) from rear engine mount. Unscrew 2 bolts (3) for support of front exhaust pipes.

Illustration shows vehicle with V6 engine.

Unscrew 2 fastening bolts for upper rear engine mount (1) and remove rear engine mount with support for front exhaust pipe (for V6-engine with both supports for front exhaust pipes).

Disconnect wiring harness plug from output speed sensor and remove wiring harness from bracket on transmission nose piece, if present. Unscrew fastening screw (1) from transmission output speed sensor.

  Inspect

Check O-ring of output speed sensor for damage, replace if necessary.

Unscrew output flange (socket A/F 30, extra long), counterhold with KM-623 (1).

Remove output flange (2) from output shaft. If tight, use Remover KM-628-A.

Caution

Check O-ring of output flange for wear and damage, replace if necessary.

  Remove

Remove transmission nose piece (arrows, 7 fastening bolts in total). Remove transmission nose piece and seal.

Caution

Fluid escapes, collect escaping fluid. Do not reuse old fluid.

For further reworking of transmission nose piece:

• Check seal ring and needle bearing, replace if necessary.
• Lever out seal ring – do not damage transmission nose piece.
• Press out needle bearing with suitable pipe.

  Install

Press new needle bearing in flush to transmission nose piece using KM-109 (1).

Press new seal ring in flush to transmission nose piece using KM-629-1 (2).

When replacing transmission extension transfer parking lock. Install retaining spring for parking lock pawl into transmission extension, as shown in illustration E 5593.

Install parking lock pawl into transmission nose piece. Doing this, install retaining spring (arrow) correctly.

Adhere seal with installation grease at transmission housing. Connect transmission nose piece at transmission housing. Make sure that actuating rod (arrow) for parking pawl is correctly inserted in transmission nose piece.

Torque

Tighten 7 fastening bolts for transmission extension – tightening torque 32 Nm / 24 lbf. ft.

  Install

Install output flange (1) onto output shaft, note O-ring.

Torque

Screw on new fastening nut and tighten – tightening torque 100 Nm / 74 lbf. ft.

Fit transmission output speed sensor with O-ring and tighten fastening bolt – tightening torque 9 Nm / 7 lbf. ft.

Connect wiring harness plug and fasten wiring harness.

Position rear engine mount with support for front exhaust pipe (for V6-engines with both supports for front exhaust pipes). Screw in 2 fastening bolts (1) for upper rear engine mount.

Torque

Fastening bolts (1) to upper rear engine mount – tightening torque 40 Nm / 30 lbf. ft.

Bolt transmission crossmember onto rear engine mount (2) and tighten – tightening torque 20 Nm / 15 lbf. ft.

Fit 2 bolts for support of front exhaust pipes (3) and tighten – tightening torque 20 Nm / 15 lbf. ft.

Attach transmission crossmember to vehicle underbody and tighten (1) – tightening torque 45 Nm/33 lbf. ft., insert screws with locking compound.

Lower hydraulic jack. Push propshaft and output flange together and fasten (3 new screws with new nuts).

Torque/angle method

Propshaft to output flange: For Torx bolts M10 – tighten in 2 stages 50 Nm / 37 lbf. ft. + 75° to 90°. For hex bolts M12 – tightening torque 95 Nm / 70 lbf. ft.

Fill in transmission fluid up to lower edge of checking/filler opening.

Torque

Install checking bolt with seal ring and tighten – tightening torque 33 Nm / 24 lbf. ft.

Lower vehicle and connect battery. Check transmission fluid level – see operation "Transmission Fluid Level, Check and Correct" in this group.