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Fitting a reconditioned gearbox to a MK2 Astra GTE 8v.

More info is available here.


Original inlet manifold on engine. First up the car was supported on axle stands. If you look closely at the left hand picture then you'll see some rope binding the engine to the strut brace. An axle stand was also placed under the sump. This is necessary because two of the three engine mounts are attached to the gearbox. So the engine needs supporting when the box is off.


The far left image shows the input shaft. This slides out and then allows the box to be separated from the clutch. The middle image shows how I managed it (the thread is an exact match with the turret bolts on the gearbox, and the end of the clutch cable). The right hand image shows the proper Vauxhall tool for the job. The input shaft can sometimes be very hard to remove.

It's a pretty uncomfortable experience changing a gearbox on a driveway.

 


As long as the car is high enough then the box can be rolled out on a jack.

My very own personal scrapyard. Most of the gearbox is actually the bell housing for the clutch and flywheel. The actual part with the gears in is pretty small. In the right hand image you can see the input shaft and the clutch release bearing. When the clutch cable is pulled then it pushes this bearing towards the clutch by means of lever. This is what causes the clutch to disengage. It is worth changing this if the clutch is being replaced. As it wears it becomes noisy.

Alignment of gear mechanism is simple if you know how. On the gearbox a drill bit is pushed into a hole on the turret. This hole has bung in it. A 6mm drill pushes home once the selector is in the correct position. Now in the car, under the gear change gaiter, there is an arrow on the plastic joint mechanism and another arrow on the housing. The gear lever has to be moved until these arrows line up. Then do up the selector pinch bolt and the gears will be correct. Well it worked for me.

More info is available here.

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