Transmission Oil; F17+Transmission; Differential Cover Plate Securing Bolts; Transmission Oil Level Plug - Opel Zafira B MPV 2006 Owners Workshop Manual

7 A•2 Manual transmission
Torque wrench settings
Nm lbfft
Differential lower cover plate bolts (F17 + transmission) ............ . 18 13
Engine/transmission mountings. . . .......................... . See the relevant Part of Chapter 2
Engine-to-transmission bolts . . ............................ . See the relevant Part of Chapter 2
Oil drain plug (M32 transmission) ............................. . 20 15
Oil filler plug (M32 transmission) ............................. .
30 22
Oil level plug (F17 + transmission):
Stage1 .............................................. . 4 3
Stage 2 ............................................ .. Angle-tighten a further 45° to 135°
Oil seal carrier to differential (M32 transmission):
Stage 1 ............................................... . 20 15
Stage 2 .............................................. . Angle-tighten a further 45°
Reversing light switch . . . . . . . . . . . . . . . . . . . ............... .
20 15
Roadwheel bolts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . 110 81
The transmission is contained in a cast-
aluminium alloy casing bolted to the engine's
left-hand end, and consists of the gearbox and
final drive differential - often called a transaxle.
Drive is transmitted from the crankshaft
via the clutch to the input shaft, which has a
splined extension to accept the clutch friction
disc, and rotates in sealed ball-bearings. From
the input shaft, drive is transmitted to the
output shaft, which rotates in a roller bearing
at its right-hand end, and a sealed ball-bearing
at its left-hand end. From the output shaft,
the drive is transmitted to the differential
crownwheel, which rotates with the differential
case and planetary gears, thus driving the
sun gears and driveshafts. The rotation of the
planetary gears on their shaft allows the inner
roadwheel to rotate at a slower speed than the
outer roadwheel when the car is cornering.
The input and output shafts are arranged
side-by-side, parallel to the crankshaft and
driveshafts, so that their gear pinion teeth
are in constant mesh. In the neutral position,
the output shaft gear pinions rotate freely,
so that drive cannot be transmitted to the
crown wheel.
Gear selection is via a floor-mounted
lever and a cable-operated selector linkage
mechanism. The selector linkage cause
the appropriate selector fork to move its
respective synchro-sleeve along the shaft,
to lock the gear pinion to the synchro-hub.
2.5 Differential cover plate securing bolts
(arrowed)- F17+ transmission
Since the synchro-hubs are splined to the
output shaft, this locks the pinion to the shaft,
so that drive can be transmitted. To ensure
that gearchanging can be made quickly and
quietly, a synchromesh system is fitted to all
forward gears, consisting of baulk rings and
spring-loaded fingers, as well as the gear
pinions and synchro-hubs. The synchromesh
cones are formed on the mating faces of the
baulk rings and gear pinions.
2 Tren~J~tmoil·
draining a11d reffltfng
1 This operation is much more efficient if
the car is first taken on a journey of sufficient
length to warm the engine/transmission up to
normal operating temperature.
Caution: If the procedure is to be carried
out on
a
hot transmission unit, take care
not to burn yourself on the hot exhaust or
the transmission/engine unit.
2 Position the vehicle over an inspection pit,
on vehicle ramps, or jack it up and support
it securely on axle stands (see Jacking and
vehicle support), but make sure that it is
level. Where fitted, remove the clips and bolts
and remove the undertray from beneath the
engine.
F17
+
transmission
Note: A new differential lower cover plate
gasket will be required for this operation.
Draining
3 Since the transmission oil is not renewed
2.8 Transmission oil level plug (arrowed) -
F17+ transmission
as part of the manufacturer's maintenance
schedule, no drain plug is fitted to the
transmission. If for any reason the transmission
needs to be drained, the only way of doing so
is to remove the differential lower cover plate.
4 Wipe clean the area around the differential
cover plate and position a suitable container
underneath the cover.
5 Evenly and progressively slacken and
remove the retaining bolts then withdraw the
cover plate and allow the transmission oil to
drain into the container (see illustration).
Remove the gasket and discard it; a new one
should be used on refitting.
6 Allow the oil to drain completely into the
container. If the oil is hot, take precautions
against scalding. Remove all traces of dirt and
oil from the cover and transmission mating
surfaces and wipe clean the inside of the
cover plate.
7 Once the oil has finished draining, ensure
the mating surfaces are clean and dry then
refit the cover plate to the transmission unit,
complete with a new gasket. Refit the retaining
bolts and evenly and progressively tighten
them to the specified torque.
Refilling
8 Wipe clean the area around the level plug.
The level plug is located behind the driveshaft
inner joint on the left-hand side of the
transmission (see illustration). Unscrew the
plug and clean it.
9 The transmission is refilled via the reversing
light switch aperture (see illustration). Wipe
clean the area around the reversing light
switch, and remove the switch as described
2.9 Fill the transmission through the
reversing light switch aperture -
F17
+
transmission