Vauxhall ASTRA Owner's Manual page 154

7.5a Prise out the retaining clip and lift the
union from the slave cylinder pipe
ring must be used on refitting (see
illustrations). Plug/cover both the union and
pipe ends to minimise fluid loss and prevent
the entry of dirt into the hydraulic system.
Note: Whilst the hose/pipe is disconnected,
do not depress the clutch pedal.
6 Remove the front exhaust downpipe,
catalytic converter and intermediate pipe, as
described in Chapter 4A, Section 18 . .
7 Detach the gearchange mechanism linkage
assembly from the top of the transmission unit
as described in Section 4.
8 Referring to
Cha~ter
8, remove both
driveshafts. If the transmission has not been
drained, be prepared for fluid loss.
9 Remove the front suspension subframe
assembly as described in Chapter 10,
ensuring that the engine unit is securely
supported by connecting a hoist to the engine
assembly. If available, the type of support bar
wh ich locates in the engine compartment side
channels is to be preferred.
10 Place a jac;k with a block of wood beneath
·he transmission , and raise the jack to take
'he weight of the transmission.
11 Unscrew the retaining bolts, and remove
' he front engine mounting bracket from the
transmission bellhousing (see ittustration).
12 Slacken and remove the si x bolts securing
:ne left-hand mounting block to the mounting
oracket on the transm ission casing, and
remove the bracket (see illustration). Using
t
e hoist or support bar, lower the trans-
'Tlission end of the assemblYJapproximately
SOmm. Ensure that the various coolant hoses
and wiring harnesses are not stretched.
13 On models where a pressed-steel sump is
7.12 Undo the six transmission mounting
bolts
7.5b The slave cylinder pipe seal must be
renewed
fitted to the engine, unbolt the flywheel cover
plate and remove it from the base of the
transmission unit.
14 Slacken and remove the upper and lower
bolts securing the transmission housing to the
engine . Note the correct fitted positions of
each bolt , and the necessary brackets, as
they are removed, to use as a reference on
refitting . Make a final check that all
components have . been disconnected , and
are positioned clear of the transmission so
that they will not hinder the removal
procedure (see illustration).
15 With the bolts removed, move the trolley
jack and transmission to free it from its
locating dowels. Once the transmission is
free, lower the jack and manoeuvre the unit
out from under the car. Remove the locating
dowels from the transmission or engine if they
are loose, and keep them in a safe place.
Refitting
16 The transmission is refitted by a reversal
of the removal procedure, bearing in mind the
following points.
a) Eilsure the locating dowels are correctly ,
positionedprior to installation.
b) Tighten all nuts and bolts,to the specified
torque (where given).
c) Renew the driveshaft oil seals (see
Section 5) before refitting the driveshafts.
d) Refit the front suspension subframe
assembly
as
described in Chapter 10.
e) Fit a new sealing ring to the transmission
clutch hydraulic pipe before clipping the
. hose/pipe end fitting into position. Ensure
the end fitting is securely retained by its
7.14 Upper transmission-to-cylinder block
bolts
Manual transmission 7 A.5
7.11 Transmission mounting-to-
bellhousing bolts
clip then bleed the hydraulic system as
described in Chapter 6.
~
If the transmission was drained, refill the
transmission with the specified type and
amount of oil, as described in Section 2. If
the oil was not drained, top-up the
transmission oil and check the level as
described in Section 9.
g) On completion, adjust the gearchange
mechanism as described in Section 3.
8 Transmi~ion overhaul -
general
information
Overhauling a manual transmission unit is a
difficult and involved job for the DIY home
mechanic. In addition to dismantling and
reassembling many small parts, clearances
must be preci sely measured and, if necessary,
changed by selecting shims and spacers .
Internal transm ission components are al so
often difficult to obtain, and in many instances,
extremely expensive. Because of this, if the
transmission develops a fault or becomes
noisy, the best course of action is to have the
unit overhauled by a specialist repairer, or to
obtain an exchange reconditioned unit.
2 Nevertheless, it is not impossible for the
more experienced mechanic to overhaul the
transmission , provided the special tools are
available, and the job is done in a deliberate
step-by-step manner, so that nothing is
overlooked .
3 The tools necessary for an overhaul include
internal and external circlip pliers, bearing
pullers, a slide hammer, a set of pin punches,
a dial test indicator, and possibly a hydraulic
press. In addition , a large, sturdy workbench
and a vice will be required .
4 During dismantling of the transmission, make
careful notes of how each component is fitted ,
to make reassembly easier and more accurate.
5 Before dismantling the transmission, it will
help if yOI,J have some idea what area is
malfunctioning . Certain problems can be
closely related to specific areas in the
transmission, which can make component
examination and replacement easier. Refer to
the Fault finding Section of this manual for
more information .