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Repair Instructions - Off Vehicle > < Selector and Shift Lever Cable Bracket Replacement

Astra J

Transmission Replacement

Special Tools

•  CH-904   Base Frame
•  DT-47648   Transmission Holder
•  EN-45059   Angle Meter
•  EN-47649   Engine Support Fixture
•  CH-49290   Engine Support Tool

For equivalent regional tools, refer to Special Tools .

Removal Procedure

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

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Note:  Do NOT disconnect engine coolant hoses.
2. Remove the radiator surge tank clip (2).
3. Remove the radiator surge tank (1).
  Position the radiator surge tank (1) aside.
4. Remove the transmission shift lever cable from transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .

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5. Disconnect backup lamp switch electrical connector (1).

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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.
6. Remove the clutch actuator cylinder front pipe retainer (1).
7. Remove the clutch actuator cylinder front pipe (2) from the clutch actuator cylinder pipe elbow.

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8. Remove the wiring harness starter motor from the transmission. Remove the 4 clips (1).

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9. Remove the 2 bracket bolts (2).
10. Remove the upper middle wiring harness starter motor bracket (1).

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11. Remove the 2 upper transmission bolts from engine (1).
12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
13. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .

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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. Assemble the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
15. Support the CH-904   base frame on a jack.
16. 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.
17. Install the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
18. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .

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19. Remove the transmission front mount from the transmission (2).
20. Remove the 2 bolts (1).

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21. Remove the transmission mount bracket - rear from the transmission (2).
22. Remove the 3 bolts (1).
23. Drain the transmission fluid. Refer to Transmission Fluid Level Inspection .
24. Disconnect the left front wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
25. Remove the front wheel drive intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement .
26. Lower the vehicle.
27. Install the EN-47649   engine support fixture . Refer to Engine Support Fixture .

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

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30. Remove the transmission mount bracket - left side. Remove the 3 transmission mount bracket bolts (1).
31. Raise the vehicle.
32. Loosen the starter motor. Refer to Starter Replacement .

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33. Remove the 3 transmission lower bolts (1, 2, 3).

Caution: Refer to Fastener Caution .
34. Install the NEW oil drain plug and tighten to 50 N·m (37 lb ft) .

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35. Place the DT-47648   transmission holder on the CH-904   base frame and pre-install the supports as shown in the illustration.
36. Pre-install the DT-47648-2   converter housing support (4) to position 2 on the base plate.
37. Pre-install the DT-47648-3   transmission housing support (2) to position 14 on the base plate.
38. Pre-install the DT-47648-5 left   support with rear transmission swivel arm (1) to position A on the base plate.
39. Pre-install the 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.
40. Attach the DT-47648   transmission holder to the transmission.
41. Align DT-47648   transmission holder under transmission.
42. Attach the swivel arms (1, 2) to the transmission.

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

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46. Remove the last transmission bolt from the engine (1).
47. Separate the transmission from the engine.
48. Lower the transmission with the transmission jack and DT-47648   transmission holder far enough to remove the transmission.

Installation Procedure

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

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4. Install the transmission lower bolts (1, 2) to the engine and tighten to 40 N·m (30 lb ft) .
5. Install the transmission bolt (3) to the engine and tighten to 60 N·m (44 lb ft) .
6. Lower the vehicle.

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7. Install the transmission mount bracket - left side. Install the 3 transmission mount bracket bolts (1) and tighten to 100 N·m (74 lb ft) .
8. Raise the engine and the transmission on the left hand side with the EN-47649   engine support fixture .

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9. Install the 3 NEW transmission mount bolts (1) but do not tighten yet.
10. Raise the vehicle.
11. Install the starter motor. Refer to Starter Replacement .
12. Install the front wheel intermediate drive shaft to the transmission. Refer to Front Wheel Drive Intermediate Shaft Replacement .
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 to transmission (2).
16. Install the 2 transmission front mount bolts (1) and tighten to 100 N·m (74 lb ft) .
17. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .
18. Lower the vehicle.
19. Remove the EN-47649   engine support fixture . Refer to Engine Support Fixture .

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20. Tighten the NEW transmission mount bolts - left side (1) a first pass to 50 N·m (37 lb ft) .
21. Tighten the NEW transmission mount bolts - left side (1) a final pass to an additional 60 - 75 degrees .

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22. Install the upper transmission to engine bolts (1) and tighten to 60 N·m (44 lb ft) .

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23. Lower the CH-49290   support tool (1) with the CH-904   base frame .
24. 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.
25. Disassemble the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
26. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement .

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27. Install the upper middle wiring harness starter motor bracket (1).
28. Install 2 wiring harness starter motor bracket bolts (2) and tighten to 22 N·m (16 lb ft) .

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29. Install the wiring harness starter motor to the transmission.
30. Install the 4 clips (1).

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31. Connect the clutch actuator cylinder front pipe (2) to the clutch actuator cylinder pipe elbow.
32. Install the clutch actuator cylinder front pipe retainer (1) to the clutch actuator cylinder pipe elbow.

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33. Connect the electrical connector (1) to the backup lamp switch.
34. Install the transmission shift lever cable to transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
35. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch System Bleeding .
36. Fill the transmission with correct fluid.
37. Inspect the transmission fluid level. Refer to Transmission Fluid Level Inspection .

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38. Install the radiator surge tank (1).
39. Install the radiator surge tank clip (2).
40. Install the battery tray. Refer to Battery Tray Replacement .
41. Road test the vehicle.

Repair Instructions - Off Vehicle > < Selector and Shift Lever Cable Bracket Replacement