Opel Astra, Zafira

since 1998 of release

Repair and car operation



Opel Astra
+ Opel Astra and Zafira Cars
+ Operation manual
+ Routine maintenance
+ Engine
+ Systems of cooling, heating
+ Power supply system and release
+ engine Electric equipment
- Manual transmission
   Specifications
   Adjustment of a drive of gear shifting
   Removal and installation of the mechanism of gear shifting
   Replacement of epiploons
   Check of serviceability of functioning, removal and installation of the sensor switch of fires of a backing
   Removal and installation of the sensor of speed (VSS)
   Replacement of transmission oil
   Removal and RKPP installation
   RKPP repair - the general information
+ Automatic transmission
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment


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Manual transmission

General information

Used on considered models of Opel Astra/Zafira cars manual boxes of transfer have a 5-step design with complete synchronization. Number of transmission is beaten out from above on a case of a box (F13, F17 and F18 model), or engraved on a back wall of the case of differential (F23).

The case of transmission is made by a molding method of an aluminum alloy, and fastens bolts to the left side of the engine. The structure of RKPP includes actually a box of gear shifting and differential (the main transfer).

The torque developed by the engine through a frictional disk of coupling is transferred to the pin of primary shaft of RKPP rotating in closed ball bearings equipped with shlitsa. From primary shaft rotation is transferred to the target (secondary) shaft which right pin is fixed in the roller bearing, and left - in closed ball. From a target shaft rotation is told to a koronchaty cogwheel (a conducted gear wheel) main transfer and assembly of differential providing possibility of rotation of driving wheels in various angular speed rigidly jointed with it that allows to avoid excessive wear of protectors during commission of turns.

Primary and secondary shaft of RKPP are located parallel to axes cranked and power shafts in such a manner that their teeths are in continuous gearing. In the provision of neutral transfer of a gear wheel of a secondary shaft are turned on it freely, excepting torque transfer on a conducted gear wheel of the main transfer.

The choice of transfers is carried out by means of the lever of the switching established on a floor of salon of the car and the mechanism of a choice of transfers. A draft/cable of the mechanism of a choice of transfers switching forks force to move, providing with that shift along assembly of primary shaft being with it in continuous gearing of couplings of synchronizers. Introduction of the coupling of the synchronizer in gearing with teeths of the corresponding gear wheel on secondary to a shaft forces the box to provide the demanded transfer relation answering to chosen transfer. The design consisting of brake rings, podpruzhinenny fingers, shesterenchaty transfers and sliding couplings of synchronizers provides to switchings necessary smoothness and noiselessness. Synchronizing cones are formed by the processed surfaces of brake rings and gear wheels.

In view of complexity of a design of RKPP, absence on free sale of necessary replaceable internal components and need of use of the special equipment, originators of the real Management do not recommend to owners of cars to carry out major maintenance of a transmission independently. Box repair in the conditions of a workshop of car-care center is rather expensive operation, and therefore, it is necessary to consider alternative options of replacement of the failed block new or restored. Any useful information on repair and replacement of transmission can be received at Opel company car repair shops. Regardless of the chosen way of elimination of problems (repair or replacement), independent dismantle of a box from the car will allow to reduce material inputs essentially.