Transmission Input/Output Speed Sensor - Opel Zafira B MPV 2006 Owners Workshop Manual

78•6 Automatic transmission
to correct the fault then the complete switch
must be renewed as a unit.
Adjustment
2 Adjustment of the switch entails the use
of Vauxhall/Opel special tool KM-962, which
is then connected to the selector lever
position switch wiring connector on the
transmission. The tool contains a series of
LEDs (light emitting diodes) that illuminate
in sequence, with the ignition switched on,
as each selector position is engaged. If the
LEDs do not illuminate correctly in each
selector lever position, the position switch
securing bolts must be slackened and the
switch repositioned accordingly. As accurate
adjustment of the position switch can only be
carried out using this tool, the work should be
entrusted to a Vauxhall/Opel dealer.
Removal
Note: It will be necessary to have the
adjustment of the switch carried out by
a
Vauxha/1/0pe/ dealer on completion (see
adjustment above). Bearing this in mind, it may
be beneficial to have the complete operation
(removal, refitting and adjustment) carried out
by the dealer at the same time.
3 Position the selector lever in the N (neutral)
position.
4 To gain access to the switch, remove
the battery and battery tray as described in
Chapter 5A.
5 Where fitted, detach the cable duct from
the wiring harness bracket situated above the
selector cable.
6 Using a forked tool or flat-bladed
screwdriver, carefully lever the selector inner
cable end fitting off the balljoint on the selector
lever position switch. Pull back the retaining
sleeve and detach the outer cable from the
mounting bracket on the transmission (see
illustration 4.3).
7 Undo the bolts securing the selector cable
mounting bracket and wiring harness support
to the transmission and move the bracket to
one side.
8 Remove the transmission fluid level dipstick
and filler tube from the transmission and
recover the gasket/0-ring. Be prepared for
fluid spillage.
9 Trace the wiring back from the switch and
disconnect it at the wiring connector. Unlock
the wiring plug by pulling the lock clip away
from the main body of the plug.
10 Unscrew the retaining nut and remove the
selector lever from the transmission selector
shaft.
11 Bend back the lockwasher then slacken
and remove the main nut and lockwasher from
the transmission selector shaft.
12 Mark the position of the switch in relation
to the transmission, then slacken and remove
the switch and wiring retaining plate bolts.
Manoeuvre the switch assembly upwards and
away from the transmission unit. ·
Refitting
13 Prior to refitting, first make sure that the
transmission selector shaft is still in the N
(neutral) position. If there is any doubt, engage
the selector lever with the transmission shaft
and move the lever fully forwards (to the P
position) then move it two notches backwards.
14 Locate the switch on the transmission
shaft in the previously-noted position, then refit
the wiring retaining plate. Refit the retaining
bolts, tightening them to the specified torque.
15 Refit the lockwasher and main nut to the
selector shaft. Tighten the nut to the specified
torque setting and secure it in position by
bending up the lockwasher against one of its
flats.
16 Refit the selector lever to the shaft and
tighten its retaining nut to the specified torque.
17 Reconnect the wiring connector, ensuring
that the wiring is correctly routed.
18 Refit the transmission fluid level dipstick
and filler tube to the transmission using a new
gasket/0-ring, if necessary.
19 Reposition the selector cable mounting
bracket and wiring harness support on the
transmission and secure with the retaining
bolts, tightened securely.
20
Refit the selector outer cable to the
mounting bracket on the transmission. Engage
the selector inner cable end fitting with the
balljoint on the selector lever, squeezing them
together with pliers if necessary.
21 Where fitted, reattach the cable duct to
the wiring harness bracket situated above the
selector cable.
22 Refit the battery tray and battery and
check the operation of the switch. If necessary,
have a Vauxhall/Opel dealer adjust the switch.
AF40 transmission
23 On the AF40 transmission, the selector
lever position switch is an integral part of
the transmission electronic control unit and
cannot be separated. Removal and refitting
procedures for the electronic control unit are
contained in Section 12.
AF22 transmission
Removal
1 The speed sensors are fitted to the top-rear
of the transmission unit. The input shaft speed
sensor is the uppermost of the two sensors.
2 To gain access to the sensors, remove
the battery and battery tray as described in
Chapter 5A.
3 Disconnect the wiring connector and wipe
clean the area around the relevant sensor.
4 Undo the retaining bolt and remove the
sensor from the transmission. Remove the
sealing ring from the sensor and discard it, a
new one should be used on refitting.
Refitting
5 Fit the new sealing ring to the sensor groove
and lubricate it with a smear of transmission
fluid.
6 Ease the sensor into position then refit the
retaining bolt and tighten it to the specified
torque setting. Reconnect the wiring connector.
7 Refit the battery tray and battery as
described in Chapter 5A.
AF40 transmission
8 On the AF40 transmission, the input and
output shaft speed sensors are located
internally within the transmission and are
not individually available. If one or both
speed sensors are diagnosed as faulty, it
will be necessary to obtain a complete new
transmission.
Note: If
a
new ECU is to be fitted, this work
must be entrusted to
a
Vauxhal//Opel dealer
or suitably-equipped specialist. It is necessary
to reset the transmission electronic control
system prior to removal, and to programme the
new ECU after installation. This work requires
the use of dedicated Vauxha/1/0pel diagnostic
equipment or
a
compatible alternative.
AF22 transmission
Removal
1 The ECU is located in the centre of the facia
in front of the selector lever assembly, and
clipped into a bracket on the heater distribution
housing. Prior to removal, disconnect the
battery negative terminal (refer to Disconnecting
the battery in the Reference Chapter).
2 Remove the selector lever assembly as
described in Section 5.
3 Detach the two air distribution ducts and
push them to the rear.
4 Unclip the ECU bracket from the heater
distribution housing, and pull out to one side.
If the wiring harness prevents the ECU from
being moved to one side, cut the cable ties
securing the harness in place. Disconnect the
ECU wiring plug, and if necessary, unclip the
ECU from the bracket.
Refitting
5 Refitting is the reverse of removal, ensuring
that the wiring is securely reconnected.
AF40 transmission
Removal
6 The combined ECU and selector lever
position switch are located on the top of the
transmission housing.
7 Ensure the handbrake is fully applied, then
move the gear selector lever to the N (neutral)
position.
8 Remove the battery and battery tray as
described in Chapter 5A.
9 Unclip the pre/post-heating system control
unit wiring harness from the battery tray
support.