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 219Labour 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 6,1The costs for this repair will be covered during the normal warranty.
The regular warranty procedure should be used for claiming Set-up-time. |
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