Vauxhall Workshop Service and Repair Manuals

Manual Transmission, Remove and Install (M32)

Applies to A 16 LER / A 16 LER / Z 16 LER / Z 16 LEL

Note:   If the transmission is replaced, the following parts must be transferred:

  Remove

3.   Detach clutch pressure line (5) from transmission Note:   Collect escaping brake fluid •   Open retaining clamp (3) •   Draw pressure line out of connector Note:   Seal pressure line with plug. •   Drive retaining clip into connector 4.   Disconnect wiring harness plug (4) for reversing lamp switch 5.   Detach wiring harness for reversing light switch (1) •   Unscrew bolt (2)

6.   Detach 2 shift cables (1) from transmission •   Detach 2x gearshift cable from shift linkage lever •   Detach 2 shift cables from retainer

8.	Dismantle gearshift assembly Note:   Cover openings in transmission

9.   Release transmission at top •   Unscrew 3x bolts (1) •   Remove wiring harness bracket (2)

10.	Attach engine bridge EN-47650

11.	Drain off transmission fluid

12.	Detach right axle shaft from intermediate shaft. Note:   Axle shaft remains in wheel hub. •   Attach axle shaft to vehicle underbody

13.	Remove intermediate shaft from transmission Note:   Close openings in transmission with plugs.

15.   Detach transmission from left engine damping block •   Unscrew 3x bolts (1)

17.   Remove rear torque support bracket •   Unscrew 2x bolts (1)

18.   Release transmission at the bottom •   Detach transmission from oil pan – Unscrew 3 M10 bolts (1) •   Unscrew bolt connection M10 (2)

19.   Place transmission fixture DT-47648 on KM-904 and assemble as shown in 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 Rear transmission support with pivot arm DT-47648-5 right (3) F Front transmission support with pivot arm

Important:   Pay strict attention to manufacturer's notice for transmission fixture DT-47648 . 20.   Attach DT-47648 to transmission Note:   Loosen all screw connections of the swivel arms and supports to the base plate before placing them under load. Rotate the supports as far down as possible by way of the spindles. •   Place DT-47648 with supports beneath the transmission •   Tighten screw connections on the supports •   Attach pivot arms (1) and (2) to transmission •   Tighten the screw connections of the pivot arms starting from the transmission to the base plate Note:   Align the pivot arms so that as a little lever force as possible is created.

21.   Removing transmission •   Unscrew 2 M12 bolts (1) •   Lay charge air pipe bracket (2) aside •   Press the engine away from the transmission and slowly lower with the hydraulic jack Note:   Do not damage wiring harnesses and attaching parts

  Install

25.   Attach transmission to engine Note:   Insert charge air pipe bracket (2). •   Tighten 2x M12 bolts (1) – Stage 1 10 Nm – Stage 2 60 Nm

27.   Fasten transmission at the bottom •   Tighten 3x bolt M10 (1) 40 Nm •   Tighten screw connection M10 (2) 40 Nm

30.   Install rear torque support bracket •   Tighten 2x bolts (1) 80 Nm + 45°

32.	Remove right intermediate shaft

33.	Attach right axle shaft to intermediate shaft

35.   Fasten left engine damping block •   Tighten 3 bolts (1) 80 Nm + 45°

36.	Detach engine bridge EN-47650

37.   Fasten transmission at the top •   Insert wiring harness bracket (2) •   Tighten 3x bolt (1) 60 Nm

39.	Install main brake cylinder

41.   Connect wiring harness plug for reversing lamp switch (4) 42.   Attach clutch pressure line (5) to transmission •   Press pressure line into connector Note:   Clamp (3) must audibly engage. 43.   Attach wiring harness for reversing light switch (1) •   Tighten bolt (2)

45.	Top up with transmission fluid

46.	Vent hydraulic clutch actuation

47.	Bleed brake system and check for leaks

48.	Transmission Shift Linkage, Adjust