Vauxhall Astra Workshop Service and Auto Repair Manuals

Attach transmission to KM-694-A (2). Attach assembly to KM-113-2 (1).

Remove fluid drain bolt (3), drain transmission fluid and collect for damage diagnosis – see operation "Transmission Fluid Condition, Check (AF 13-II/AF 17/AF 20/AF 22)".

Remove converter – see operation "Converter and/or Fluid Pump Seal Ring, Replace (AF 13-II/AF 17/AF 20/AF 22)".

Remove cover plate (1) from side cover and transmission.

Remove fluid temperature sensor (2).

Remove auxiliary housing cover (3) from transmission.

Remove plug – M8 (5). Remove plug – M18 (4). Replace seal rings of plugs.

Remove fluid pump assembly (1) with multi-disc brake B1 and B2 – see operation "Fluid Pump Assembly with Multi-disc Brakes B1 and B2, Remove and Install (AF 20)".

Remove freewheel F1 (2) – see operation "Freewheel F1, Remove and Install (AF 20)".

Remove auxiliary housing (3) from main housing – 15 fastening bolts, note different bolt lengths. If necessary, detach housing parts with plastic hammer.

  Clean

Clean all components and check for wear and damage – replace affected components, if necessary.

Pull roller bearing (arrow) out of auxiliary housing with KM-J-26941 (3), KM-313 (1) and KM-483 (2) – heat auxiliary housing with hot air blower, if necessary.

Remove pipe clamp (6) for fluid line. Release pipe ends with large screwdriver – do not bend pipe. If necessary, remove pipe with KM-J-7004 and KM-586. Remove fastening bolts (4) for fluid baffle plate from auxiliary housing. Remove fluid baffle plate with magnets (on underside of fluid baffle plate). Remove cut seal ring from pin in housing (5).

Attach 3 magnets to underside of fluid baffle plate. Attach fluid baffle plate to auxiliary housing – insert fastening bolts (2) with locking compound, tightening torque 6 Nm / 4 lbf ft.

Carefully drive fluid line into auxiliary housing with plastic hammer – avoid deformation. Attach fluid line to auxiliary housing with pipe clamp (1) – tightening torque 6 Nm / 4 lbf ft. Attach new cut seal ring (3) to pin in housing – do not expand seal ring more than necessary.

Press new roller bearing into auxiliary housing with KM-629-1 (5) and drift (4) until bearing lower edge touches the housing floor.

Coat sealing surface on main housing with sealing compound. Attach auxiliary housing (1) to main housing – 15 fastening bolts, note different bolt lengths.

Torque

Auxiliary housing to main housing – 30 Nm / 22 lbf. ft.

  Install

Install freewheel F1 (2) – see operation "Freewheel F1, Remove and Install (AF 20)".

Install fluid pump assembly (1) with multi-disc brake B1 and B2 – see operation "Fluid Pump Assembly with Multi-disc Brakes B1 and B2, Remove and Install (AF 20)".

Install plug – M8 (2) with new seal ring – tightening torque 8 Nm / 6 lbf. ft. Install plug – M18 (1) with new seal ring – tightening torque 35 Nm / 26 lbf. ft.

Coat sealing surfaces with sealing compound and attach auxiliary housing cover (3) to transmission – tightening torque 8 Nm / 6 lbf. ft. Attach fluid temperature sensor (4) to transmission – tightening torque 10 Nm / 7.5 lbf. ft. Attach cover plate (5) to side cover and transmission – tightening torque 25 Nm / 18 lbf. ft.

Attach fluid drain bolt (3) with new seal ring to transmission – tightening torque 40 Nm / 29.5 lbf. ft.

Remove transmission assembly from KM-113-2 (1) with KM-694-A (2).

Remove transmission from KM-694-A.

Install transmission – see operation "Transmission, Remove and Install (AF 20)".

  Inspect

Check and correct level of transmission fluid – see operation "Transmission Fluid Level, Check and Correct (AF 13-II/AF 17/AF 20/AF 22)".