Field Remedy: 1264
| Subject: | Intermediate shaft - Leak at the bearing cap |
|---|
| Models: | Engines: | Option: |
|---|---|---|
| Vectra-B 99,Astra-G 99 | X20DTL| X20DTH| X20XEV| X25XE,X20DTL| X20XEV | F23 Transmission |
| Complaint: | Oil leaking at clutch bell housing. Clutch can slide. Transmission can be damaged by lack of oil. |
|---|---|
| Cause: | Leak at bearing cap of intermediate shaft, because cap is not pressed in correctly. |
| Production: | Improved transmissions were installed in the production starting with the following VINs: Astra-G MY 99: Bochum X2 237556, Antwerp X5 237583, Ellesmere Port X8 113902 Vectra-B MY 99: Rüsselsheim X1 113282, Luton X7 046926 |
Remedy:
Replacement of cap of intermediate shaft.
There are two possibilities of working procedure, in both cases is the following preparation necessary:
Remove front-axle-body - see working procedure "Remove and install front- axle-body" in unit "E" of the respective Service Instruction, (axle-shaft remain in the transmission and wheel hub).
1. Lower powertrain on left hand side 2. Drain transmission oil and measure quantity of oil.
If oil quantity is <1400 cm³, proceed as following: Replacement of tranmission, clutch disk and thrust plate.
3. Remove transmission - see working procedure "Remove and install transmission" unit "K" of the respective Service Instruction.
4. Replace clutch disk and thrust plate and clean flywheel - see working procedure "Replace clutch disk and thrust plate" of the respective Service Instruction.
5. Alter switch-reverse light - see working procedure "Replace or seal switch-reverse light" unit "K" of the respective Service Instruction.
If oil quantity is >1400 m³, replace the bearing cap of intermediate shaft.
3. Knock a hole into the bearing cap (2) by use of a mandrel (1).
In no case the hole my be drilled, because drill or chips may damage the transmission. 4. Screw KM-6101 (3) in connection with KM-328-B (4) into bearing cap and knock out bearing cap. 5. Remove oil pipe (arrow). 6. Insert new oil pipe. 7. Knock new bearing cap using KM-6202 (6) in connection with KM- 523-1 (5) into transmission.
8. Replace clutch disk and thrust plate and clean flywheel - see working procedure "Replace clutch disk and thrust plate" of the respective Service Instruction.
9. Install transmission - see working procedure "Remove and install transmission" unit "K" of the respective Service Instruction. Parts: Part-No.: Catalog-No.: Cap 09120610 07 02 371 Oil Pipe 09120609 07 02 370 Transmission oil 09120541 19 40 768
Labour Times: TC: Hours:
T8 126 40 Replace bearing cap Astra-G 92 5.2hrs +: Replace clutch disk
001 Additional work at cars 0.2hrs with lower engine cover
T8 126 41 Replace transmission and clutch disk Astra-G 92 5.4hrs
001 Additional work at cars 0.2hrs with lower engine cover
T8 126 42 Replace bearing cap Vectra-B(X20XEV) 92 5.7hrs +: Replace clutch disk
001 Additional work at cars 0.2hrs with lower engine cover
T8 126 43 Replace transmission and clutch disk Vectra-B(X20XEV) 92 5.8hrs
001 Additional work at cars 0.2hrs with lower engine cover
T8 126 44 Replace bearing cap Vectra-B(X20DTH/ 92 5.3hrs +: Replace clutch disk X20DTL)
001 Additional work at cars 0.2hrs with lower engine cover
T8 126 45 Replace transmission and clutch disk (Vectra-BX20DTH/ 92 5.5hrs X20DTL) 001 Additional work at cars 0.2hrs with lower engine cover
T8 126 46 Replace bearing cap Vectra-B (X25XE) 92 5.6hrs +: Replace clutch disk
001 Additional work at cars 0.2hrs with lower engine cover
T8 126 47 Replace transmission and clutch disk Vectra-B(X25XE) 92 5.7hrs
001 Additional work at cars 0.2hrs with lower engine cover
The regular warranty procedure should be used for claiming Set-up-time.
| FunctionalGroup: | K - Clutch/Transmission |
|---|---|
| Complaint Group: | 10 - Leakages |
| Trouble Code: | Non |