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Vauxhall Workshop Service and Repair Manuals

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Transmission, Remove and Install (Z16LET/M32) > < Replace gearshift cable clamping pieces (M20/M32)

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Transmission, Remove and Install (Z17DTH/M32)

  Remove

1.   Remove battery support
Object Number: 8125328 Size: DEFAULT

2.   Detach 2x gearshift cables (2) from transmission
•   Detach 2x gearshift cable from shift linkage lever
•   Remove 2x shift cable from counterhold
– Draw 2x retaining ring (1) backwards

Object Number: 8125322 Size: DEFAULT

3.   Detach pressure line (2) from transmission
Note:   Collect any escaping brake fluid.
•   Open retaining clamp (1)
•   Draw pressure line out of connector
•   Push retaining clamp into connector

4.   Disconnect wiring harness plug for reversing lamp switch
5.   Release 3x wiring harness bracket from transmission at top
•   Remove 3x bolts
•   Detach cable ties
Object Number: 10678768 Size: DEFAULT

6.   Release transmission at top
•   Unscrew 3x bolt (1) with DT-48783

7.   Detach lower engine cover
Note:   If present.
Object Number: 2414110 Size: DEFAULT

8.   Attach KM-6001-B to front axle body
Note:   The guide pins must sit in the support bearing with no play.
•   Release 2x bolt (arrows) for adjustment rails on KM-6001-B (1)
•   Insert KM-6001-B as shown
Note:   2x journals (2) and (5) must sit flush in the guide holes of the front axle body.
•   Tighten 2x bolt for adjustment rails
•   Twist up front support bearing (4)
– until the guide pin is in contact with the front of the engine damping block
•   Twist up rear support bearing (3)
– until the guide pin is in contact with the rear of the engine damping block

9.   Remove front axle body
10.   Detach right axle shaft from intermediate shaft LUREF_1.gif
•   Attach axle shaft to vehicle underbody
11.   Remove intermediate shaft
Note:   Place collecting pan underneath - transmission fluid will escape
12.   Remove left axle shaft
•   Attach axle shaft to vehicle underbody
13.   Detach transmission from left engine damping block
•   Unscrew 3x bolt (1)
Object Number: 10678769 Size: DEFAULT


Important:   Do not damage wiring harnesses and attaching parts
14.   Lower engine and transmission on the left hand side
•   lower with MKM-883-1-A
15.   Detach front engine damping block bracket
•   Unscrew 2x bolt (1)
16.   Detach rear engine damping block bracket
•   Unscrew 3x bolt (2)
Object Number: 10677782 Size: DEFAULT


Object Number: 10679390 Size: DEFAULT

17.   Place transmission holder DT-47648 on KM-904 and preinstall as shown in the illustration:

Component

Position on base plate

Designation

DT-47648-2

(4)

2

Clutch housing support

DT-47648-3

(2)

14

Transmission housing support

DT-47648-5 left

(1)

A

Support with rear transmission swivel arm

DT-47648-5 right

(3)

F

Support with front transmission swivel arm

Important:   It is essential to follow the manufacturer's instructions for transmission holder DT-47648 .
18.   Attach DT-47648 to transmission
Note:   Before placing in position, slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports using the spindles until they are as low as possible.
•   Place DT-47648 with supports in position under the transmission
•   Tighten bolt connections of the supports
•   Attach swivel arm (1) and (2) to transmission
•   Tighten bolt connections of the swivel arms starting from the transmission and going as far as the base plate
Note:   Align the swivel arms so that as little leverage as possible is created.
Object Number: 10679398 Size: DEFAULT


Object Number: 8125319 Size: DEFAULT

19.   Remove transmission
•   Unscrew 4x bolt (1)
•   Press transmission off engine and slowly lower the hydraulic jack
Note:   Do not damage wiring harnesses and attaching parts

Important:   Do not damage attaching parts when putting the transmission down.
20.   Detach transmission from transmission holder DT-47648
Note:   2nd mechanic required.
•   Unscrew 2x bolt
•   Put transmission down carefully

  Install

21.   Attach transmission to transmission holder DT-47648
Note:   2nd mechanic required.
•   Tighten 2x bolt
22.   Install transmission with DT-47648
•   Raise transmission and align it
•   Place transmission so that it is in even contact with the engine
Note:   Ensure it is seated perfectly.
Object Number: 10677766 Size: DEFAULT

23.   Fasten transmission at the bottom
•   Tighten 2x bolt M12 (1)
– Stage 1 10 Nm
– Stage 2 60 Nm

24.   Detach transmission holder DT-47648 from transmission
•   Unscrew 2x bolt
•   Lower hydraulic jack with transmission holder DT-47648 and extend
Object Number: 10677767 Size: DEFAULT

25.   Fasten transmission at the bottom
•   Tighten 2x bolt M10 (1) 40 Nm
Note:   Note differing bolt lengths

Important:   Do not damage wiring harnesses and attaching parts
26.   Raise engine and transmission on the left hand side
•   Raise with MKM-883-1-A
27.   Attach transmission to left hand engine damping block
•   Screw in 3x bolt (1)
Note:   Do not tighten bolts yet
Object Number: 10678769 Size: DEFAULT


28.   Attach front engine damping block bracket
•   Tighten 2x bolt (1) 80 Nm
29.   Attach rear engine damping block bracket
•   Tighten 3x bolt (2) 80 Nm
Object Number: 10677782 Size: DEFAULT


30.   Fit left axle shaft
31.   Install intermediate shaft
32.   Attach right axle shaft to intermediate shaft LUREF_1.gif
33.   Install front axle body
Note:   Do not detach MKM-883-1-A yet.
34.   Fasten left engine damping block
•   Tighten 3x bolt (1) 55 Nm
Object Number: 10678769 Size: DEFAULT


35.   Detach KM-6001-B from front axle body
Object Number: 10678768 Size: DEFAULT

36.   Fasten transmission at top
•   Tighten 3x bolt (1) with DT-48783 60 Nm

37.   Connect wiring harness plug for reversing lamp switch
38.   Attach 3x wiring harness bracket to transmission at top
•   Tighten 3x bolt
•   Fasten cable tie
Object Number: 8125328 Size: DEFAULT

39.   Attach 2x shift cable (2) to transmission
•   Suspend 2x shift cable in counterhold
– Press 2x retaining ring (1) towards the rear
•   Attach 2x shift cable to shift linkage lever

40.   Correct transmission fluid level LUREF_1.gif
41.   Attach lower engine cover
Note:   If necessary.
42.   Bleed hydraulic clutch actuation LUREF_1.gif
43.   Transmission Shift Linkage, Adjust LUREF_1.gif
44.   Install battery support
45.   Program volatile memories

Transmission, Remove and Install (Z16LET/M32) > < Replace gearshift cable clamping pieces (M20/M32)