Field Remedy: 2305

Remedy:

In case of one or several customer complaints described above 
the shift fork for the 3rd/4th gear has to be replaced. If a tough 
gear shift is complained the following check has to be carried out 
before repair:

- start engine
- shift 1st gear
- stop engine
- disengage 1st gear and shift again

If a tough gear shift occurs during this check the shift 
fork 3rd/4th gear is bent and has to be replaced.

Note: The reinforced shift fork is available via P&A.

Working procedure:

 1. Remove transmission

    - see working procedure "Transmission, Remove and Install",
      group "K" of accordant Service Instruction.

 2. Loosen transmission housing cover (picture I)

    - Unscrew 16x screw (arrows)

 3. Remove transmission housing cover (picture II)

    - Loosen cover (1) with suitable tool (2,3) from transmission 
      housing.

    Note:
    No beating or trashing onto the cover or the transmission housing.

 4. Spray seal remover onto sealing area between cover and 
    transmission housing and let it expose for about 15 min.

    Note:
    Use implicitly seal remover Loctite 7200 (order at your local 
    Loctite retailer).

 5. Remove reverse lamp switch (1, picture III).

 6. Remove gear shift assembly (1, picture IV).

    - Shift transmission into neutral position
    - Unscrew 2x screw (2)

 7. Remove control rod (1) of primary shaft (picture V)

    - Degrease control rod with silicone remover
    - Apply several layers of adhesive tape (2) onto control rod
    - Attach 1x cable strap (3) to avoid sliding
    - Grab control rod with pliers on the covered point and remove it
      upwards.

    Note:
    Implicitly avoid to damage the connecting rod.

 8. Remove shift fork 3rd/4th gear (1) upwards (picture VI).

 9. Clean 16x thread in transmission housing

    - Clean threads with final thread cutter und blow out with
      compressed air.

    Note:
    To avoid dirt contamination inside of the transmission the 
    gear train has to be covered with a clean tissue.

10. Clean magnet (1) in transmission housing (picture VII).

11. Install new shift fork 3rd/4th gear into transmission.

12. Install control rod (1) of primary shaft (picture VIII)

    - Remove cable strap and adhesive tape from control rod
    - Clean control rod with silicone remover from adhesive rests
    - Assemble control rod carefully with plastic hammer.

    Note:
    Attend that shift forks (2) adjoin on the shifting sleeve during
    assembling. Avoid to cant the control rod.

13. Install gear shift assembly

    - Screw in 2x screw and tighten 21 Nm.

14. Install reverse lamp switch

    - Screw in switch and tighten 20 Nm.

15. Clean sealing area between cover and transmission housing

    - Remove seal remover and rests of sealing compound with a clean 
      tissue from sealing area.

16. Apply sealing compound (1) uninterrupted with a thickness 
    of 2-3 mm onto cover transmission housing (picture IX)

    Note:
    Use silicone sealing compound (part number 90543772 /
    catalogue number 15 03 298).

17. Install cover transmission housing (picture X)

    - Attach cover transmission housing without misalignment
    - Screw in 16x screw with hand.

    Note:
    Place in screw (16) implicitly in its original position.

18. Tighten 16x screw in two steps according to tightening sequence 
    (picture X)

    - Step 1: 5 Nm
    - Step 2: 21 Nm
    - For verification tighten all screws clockwise with 21 Nm.

19. Carry out a functional check

    - Mount clutch plate
    - Shift each gear and rotate transmission at input shaft.

20. Install transmission

    - see working procedure "Transmission, Remove and Install",
      group "K" of accordant Service Instruction.

Spare-Parts:                          Part-No.:         Catalogue-No.:

Reinforced shift fork                 55570787           7 34 000          
Seal remover Loctite 7200             Loctite retailer
Silicone sealing compound             90543772          15 03 298
Transmission oil (1 litre)            9120541           19 40 768
Transmission oil (60 litre)           9194349           19 40 710
Transmission-oil drain bolt           93180976           7 02 929
Transmission-oil filler bolt          90446270           7 02 219

Labour Times:                              TC:            Hours:

Astra-H M32 / Z16LET

U3 230 50      Replacement shift fork      90             5,6

Astra-H M32 / Z20LEH, Z20LEL, Z20LER

U3 230 50      Replacement shift fork      90             5,4

Astra-H M20 / Z13DTH

U3 230 50      Replacement shift fork      90             5,4

Astra-H M32 / Z17DTH

U3 230 50      Replacement shift fork      90             6,6

Astra-H M32 / Z19DT, Z19DTL

U3 230 50      Replacement shift fork      90             6,5

Astra-H M32 / Z19DTH

U3 230 50      Replacement shift fork      90             6,4

Corsa-D M32 / Z16LER

U3 230 50      Replacement shift fork      90             4,8

Corsa-D M20 / Z13DTH

U3 230 50      Replacement shift fork      90             4,8

Meriva M32 / Z16LET

U3 230 50      Replacement shift fork      90             4,8

Signum / Vectra-C M32 / Z22YH

U3 230 50      Replacement shift fork      90             5,3

Signum / Vectra-C M32 / Z19DT, Z19DTL

U3 230 50      Replacement shift fork      90             5,4

Zafira-B M32 / Z20LEH

U3 230 50      Replacement shift fork      90             5,2

Zafira-B M32 / Z20LER

U3 230 50      Replacement shift fork      90             5,1

Zafira-B M32 / Z22YH

U3 230 50      Replacement shift fork      90             5,3

Zafira-B M32 / Z19DT, Z19DTH, Z19DTL

U3 230 50      Replacement shift fork      90             6,1

The costs for this repair will be covered during the normal warranty.
The regular warranty procedure should be used for claiming 
Set-up-time.