7B•1
Chapter 7 Part B:
Automatic transmission
Contents
Automatic transmission - removal and refitting . . . . . . . . . . . . . . . . . 9
Automatic transmission fluid level check . . . . . . . . . . . .See Chapter 1
Automatic transmission overhaul - general information . . . . . . . . . . 10
Fluid cooler - general information . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Selector lever assembly - removal and refitting . . . . . . . . . . . . . . . .
Selector linkage - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selector linkage - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .
Transmission control system electrical components - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission fluid - draining and refilling . . . . . . . . . . . . . . . . . . . . .
5
3
4
8
2
Degrees of difficulty
Easy, suitable for
novice with little
experience
1
Fairly easy, suitable
for beginner with
some experience
2
Fairly difficult,
suitable for competent
DIY mechanic
3
Difficult, suitable for
experienced DIY
mechanic
4
Very difficult,
suitable for expert DIY
or professional
5
Specifications
General
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four-speed electronically-controlled automatic with three (normal,
sport and winter) driving modes
Identification code*:
2.0 and 2.5 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR25
3.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR35
*The code is marked on the identification plate which is attached to the left-hand side of the transmission unit, behind the selector lever.
Torque wrench settings
Nm
Engine-to-transmission support bracket bolts - 2.0 litre engines with one-piece sump:
Bracket-to-engine bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Bracket-to-transmission bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fluid cooler pipe unions:
Union bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Union nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fluid filter retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fluid level plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Output speed sensor bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Propeller shaft centre bearing bracket bolts . . . . . . . . . . . . . . . . . . . . . 20
Propeller shaft flange nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Rear mounting crossmember-to-body bolts . . . . . . . . . . . . . . . . . . . . . 45
Selector lever position switch bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Selector linkage fixings:
Linkage rod clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lever pivot shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lever to transmission selector shaft nut . . . . . . . . . . . . . . . . . . . . . . . 20
Sump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque converter-to-driveplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Transmission unit mounting bolts:
Transmission-to-cylinder block bolts . . . . . . . . . . . . . . . . . . . . . . . . . 60
Transmission-to-sump flange bolts
(engines with a two-piece sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1 General information
Note: On later models, if the battery is
disconnected with the selector lever in the P
position, the lever will be locked in position. To
manually release the lever, carefully unclip the
selector lever gaiter from the top of the centre
console then, depress the yellow release lever
on the left-hand side of the selector lever with
a pen or screwdriver (see illustrations). The
selector lever can then be moved as normal.
1 Most models covered in this manual were
offered with the option of a four-speed,
3510 Vauxhall/Opel Omega
Ibf ft
30
16
18
22
15
24
9
15
74
33
10
6
21
15
9
22
44
30
electronically-controlled automatic transmission, consisting of a torque converter, an
epicyclic geartrain, and hydraulically-operated
clutches and brakes. The unit is controlled by
the electronic control unit (ECU) via
electrically-operated solenoid valves. The
transmission unit has three driving modes;
normal (economy), sport and winter modes.
7B
7B•2 Automatic transmission
2 Transmission fluid draining and refilling
3
1.0a On later models, to release the
selector lever from the P position with the
battery disconnected, unclip the selector
lever gaiter . . .
1.0b . . . then depress the yellow release
lever (arrowed) on the selector lever
mounting
2 The normal (economy) mode is the
standard mode for driving in which the
transmission shifts up at relatively low engine
speeds to combine reasonable performance
with economy. If the transmission unit is
switched into sport mode, using the button
on the selector lever, the transmission shifts
up only at high engine speeds, giving
improved acceleration and overtaking
performance. When the transmission is in
sport mode, the indicator light in the
instrument panel is illuminated. If the
transmission is switched into winter mode,
using the button on the centre console, the
transmission will be select third gear as the
vehicle pulls away from a standing start; this
helps to maintain traction on very slippery
surfaces.
3 The torque converter provides a fluid
coupling between engine and transmission,
which acts as an automatic clutch, and also
provides a degree of torque multiplication
when accelerating.
4 The epicyclic geartrain provides either of
the four forward or one reverse gear ratios,
according to which of its component parts are
held stationary or allowed to turn. The
components of the geartrain are held or
released by brakes and clutches which are
activated by the control unit. A fluid pump
within the transmission provides the
necessary hydraulic pressure to operate the
brakes and clutches.
5 Driver control of the transmission is by a
seven-position selector lever. The drive D
position,
allows
automatic
changing
throughout the range of all four gear ratios. An
automatic kickdown facility shifts the
transmission down a gear if the accelerator
pedal is fully depressed. The transmission
also has three hold positions, 1 means only
the first gear ratio can be selected, 2 allows
both the first and second gear ratios position
to be automatically selected and 3 allows
automatic changing between the first three
gear ratios. These hold positions are useful for
providing engine braking when travelling
down steep gradients. Note, however, that the
transmission should never be shifted down a
position at high engine speeds.
6 If the ECU senses a fault in the transmission
operation it will illuminate the warning light on
the instrument panel and the relevant fault
code will be stored in the ECU memory. If the
warning light comes on, the vehicle should be
taken to a Vauxhall dealer at the earliest
opportunity. A complete test of the
transmission unit can then be carried out,
using a special electronic diagnostic test unit
which is simply plugged into the system’s
diagnostic connector. The connector is
located behind the fusebox cover panel on
the drivers’ side of the facia.
7 Due to the complexity of the automatic
transmission, any repair or overhaul work
must be left to a Vauxhall dealer. The contents
of the following Sections are therefore
confined to supplying general information,
and any service information and instructions
that can be used by the owner.
Note: A new main sump gasket will be
required for this operation. If the intermediate
sump is also to be removed, obtain a new
gasket for that as well.
1 Since the transmission fluid is not renewed
as part of the manufacturers 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 main sump
and, if necessary, the intermediate sump.
2 Park the vehicle on level ground, switch off
the ignition, and apply the handbrake firmly.
For improved access, jack up the front of the
car and support it securely on axle stands but
note that the vehicle must be level when the
transmission is refilled.
3 Position a container under the fluid level
plug on the right-hand side of the transmission main sump. Unscrew the plug and
remove it along with its sealing washer (see
illustration).
4 Allow the fluid to drain out into the container
then refit the level plug (see illustration).
5 Bearing in mind that the sump will still be full
of oil, position a large container underneath
the main sump. Evenly and progressively
slacken and remove the sump retaining bolts,
noting the correct location of the cooler pipe
retaining clip(s) (see illustration). Carefully
remove the sump and empty its contents into
the container. Remove the gasket and discard
it; a new one should be used on refitting.
6 To drain the transmission unit completely,
slacken and remove the retaining bolts, then
remove the intermediate sump from the
transmission unit and empty its contents into
the container. Remove the gasket and discard
it; a new one should be used on refitting.
7 Whilst the main sump is removed, take the
opportunity to check the transmission fluid
filter. Undo the three retaining bolts, then
remove the filter from the underside of the
transmission (see illustrations). Clean the
filter element in a bath of solvent, then
examine the element for signs of clogging or
damage. If the filter element is split or blocked
2.3 Slacken and remove the fluid level
plug from the main sump . . .
2.4 . . . and allow the transmission fluid to
drain into a suitable container
2.5 Unscrew the retaining bolts and
remove the main sump from the
transmission unit
3510 Vauxhall/Opel Omega
Automatic transmission 7B•3
2.7a Undo the retaining bolts (arrowed) . . .
2.7b . . . and remove the fluid filter from
the transmission unit
or its seal is damaged, then the filter must be
renewed (the seal is not available separately).
8 Remove all traces of dirt and fluid from the
sump and transmission mating surfaces and
wipe clean the inside of the sump(s). Remove
the magnet from inside the main sump and
clean all traces of metal filings from it; the
filings should be very fine - any sizeable chips
of metal indicate a worn component in the
transmission (see illustration). Also remove
all traces of locking compound from the
threads of the sump retaining bolts.
9 Ensure that the filter element and
transmission mating surfaces are clean and
dry. Offer up the filter to the transmission then
refit the retaining bolts and tighten them to the
specified torque.
10 Where necessary, ensure the mating
surfaces are clean and dry then refit the
intermediate sump to the transmission unit,
complete with a new gasket (see illustration).
Apply a drop of thread locking compound
(Vauxhall recommend the use of locking
compound 15 10 181 - available from your
Vauxhall dealer) to the each of the retaining
bolts then refit the bolts, tightening them
evenly and progressively to the specified
torque setting.
11 Ensure the mating surfaces of the main
sump and transmission unit are clean and dry.
Fit a new gasket to the sump and apply a drop
of thread locking compound (Vauxhall
recommend the use of locking compound 15
10 181 - available from your Vauxhall dealer)
to the each of the retaining bolts. Offer up the
sump and gasket then refit the bolts,
tightening them evenly and progressively to
the specified torque setting (see illustration).
12 Refilling the transmission is an awkward
operation, adding the specified type and
amount of fluid to the transmission a little at a
time via the level plug hole in the main sump.
Ensure that the vehicle is level then fill the
transmission with new fluid of the specified
type allowing plenty of time for the fluid level
to settle properly. Once the fluid level is up to
the base of the level plug aperture with the
engine stopped, it will be necessary to start
the engine and add the rest of the fluid with
the engine running.
13 Start the engine and allow it to idle then
carefully add the rest of the fluid. Once the
fluid level is up to the base of the level plug
aperture, refit the level plug and sealing
washer and tighten to the specified torque.
14 Take the car on a short run to fully
distribute the new fluid around the
transmission, then recheck the fluid level as
described in Chapter 1 with the transmission
at normal operating temperature. Once the
fluid level is correct fit a new sealing washer to
the level plug then refit the plug and tighten it
to the specified torque.
2.10 Refit the intermediate sump using a
new gasket
2.8 Clean all traces of metal fillings from
magnet which is fitted inside the main
sump
selector lever position indicator. If adjustment
is necessary, continue as follows.
2 Position the selector lever in the P (park)
position. Firmly apply the handbrake then jack
up the front of the vehicle and support it on
axle stands.
3 Locate the selector lever on the left-hand
side of the transmission unit and slacken the
clamp bolt at the transmission end of the
linkage rod (see illustration). Pull the
transmission selector lever fully backwards to
ensure it is located in the P (Park) position
then tighten the linkage rod clamp bolt to the
specified torque.
4 Check the operation of the selector lever
and the position indicator switch. If necessary,
adjust the switch as described in Section 8
then lower the vehicle to the ground.
4 Selector linkage removal and refitting
3
Removal
1 Operate the selector lever throughout its
entire range and check that the transmission
engages the correct gear indicated on the
1 Firmly apply the handbrake then jack up the
front of the vehicle and support it on axle
stands.
2 Slide off the retaining clips then free the
linkage rod from the transmission and selector
lever and manoeuvre it out from underneath
the vehicle (see illustration). Recover the
bushes which are fitted to the lever pivot pins
and renew them if they show signs of wear or
damage.
2.11 Ensure the mating surfaces are clean
and dry then refit the main sump complete
with a new gasket
3.3 Slacken the clamp bolt (arrowed) and
adjust the selector linkage as described in
text
3 Selector linkage adjustment
3510 Vauxhall/Opel Omega
3
7B
7B•4 Automatic transmission
Refitting
4.2 Slide off the retaining clip (arrowed)
and detach the selector linkage rod from
the selector lever
Refitting
3 Apply a smear of multi-purpose grease to
the linkage rod pivot pins. Ensure the bushes
are in position then refit the rod to the
transmission and selector lever and secure it
in position with the retaining clips.
4 Check the operation of the selector linkage
and, if necessary, adjust as described in
Section 3 before lower the vehicle to the
ground.
5 Selector lever assembly removal and refitting
3
Note: Renewal of the lever switches is
covered in Section 8
Removal
Note: A pop rivet gun and new rivets will be
required on refitting.
1 Remove the centre console as described in
Chapter 11 then position the selector lever in
the P (park) position.
2 Firmly apply the handbrake then jack up the
front of the vehicle and support it on axle
stands.
3 Slide off the retaining clip and detach the
selector linkage rod from the base of the lever.
Take care not to lose the lever pivot bush.
4 Slacken and remove the retaining nuts and
bolt then remove the front and rear support
brackets from the rear heater/ventilation duct.
Unclip the duct and remove it from the around
the selector lever.
5 Disconnect the wiring connector from the
selector lever mode switch and unclip the
wiring so that it is free to be removed with the
lever. On later models were the lever is fitted
with a selector lever pawl, remove the pawl
switch and the ignition key release switch as
described in Section 8.
6 Carefully drill off the heads from the rivets
securing the lever mounting plate to the floor
then ease the selector lever out of position.
Recover seal (where fitted) which is fitted
between the housing and floor.
7 Inspect the selector lever mechanism for
signs of wear or damage and renew worn
components as necessary
8 Ensure the mating surfaces of the lever
mounting plate and body are clean and dry.
Where a seal was fitted between the mounting
plate and body ensure the seal is in good
condition then position it on the body. Where
no seal was fitted apply and thin film of
sealant to the mating surface of the mounting
plate to ensure a water-tight seal.
9 Manoeuvre the lever assembly into position
and seat it on the body. Locate all the new
pop rivets in the mounting plate holes to
ensure the lever is correct positioned then
secure all the rivets in position with a pop rivet
gun.
10 Ensure the lever mode switch wiring is
correctly routed then reconnect its connector.
Where necessary, refit the pawl switch and
the ignition key release switch as described in
Section 8.
11 Clip the rear heater/ventilation duct back
into position then refit the support brackets,
tightening their retaining bolt/nuts securely.
12 Refit the centre console as described in
Chapter 11.
13 Ensure the pivot bush is correctly
positioned then reconnect the linkage rod to
the transmission selector lever and secure it in
position with the retaining clip.
14 Check the operation of the selector
linkage and, if necessary, adjust as described
in Section 3 before lower the vehicle to the
ground.
6 Oil seals renewal
4
Propeller shaft flange oil seal
Note: A new flange sealing ring and retaining
nut will be required.
1 Working as described in Chapter 8, free the
front end of the propeller shaft from the
transmission flange and remove the vibration
damper (where fitted). If necessary, to
improve access to the flange remove the shaft
completely.
2 To prevent the rotation as the shaft nut is
slackened bolt a length of bar with two holes
drilled in it to the flange. Alternatively, a tool
can be fabricated from two lengths of steel
strip (one long, one short) and a nut and bolt;
the nut and bolt forming the pivot of a forked
tool.
3 Hold the flange then slacken and remove
the retaining nut from the end of the
transmission main shaft. Remove the holding
tool and slide off the flange complete with its
sealing ring. Discard the nut and sealing ring;
new ones should be used on refitting.
4 Note the correct fitted depth of the seal in
the transmission housing then carefully prise it
out of position using a large flat-bladed
screwdriver.
5 Check the propeller flange sealing surface
3510 Vauxhall/Opel Omega
for signs of wear or damage. If there is visible
signs of damage, renew the flange.
6 Clean all traces of dirt from the area around
the oil seal aperture then apply a smear of
grease to the outer lip of the new oil seal.
7 Making sure its sealing lip is facing inwards,
slide the new seal over the main shaft end and
tap it squarely into position, using a suitable
tubular drift (such as a socket) which bears
only on the hard outer edge of the seal.
Ensure the seal is positioned at the same
depth in the housing that the original was.
8 Fit the new sealing ring to the flange then
lubricate the seal with a smear of transmission
oil. Carefully slide the propeller flange into
position, taking care not to damage the seal
lip. Fit the new nut and tighten it to the
specified torque using the method employed
on removal to prevent rotation.
9 Reconnect/refit the propeller shaft as
described in Chapter 8.
10 Take the vehicle on a short run then check
the transmission fluid level as described in
Chapter 1.
Selector shaft oil seal
11 Remove the selector lever position switch
as described in Section 8.
12 Using a small flat-bladed screwdriver,
carefully lever the oil seal out from the housing
then slide it off of the shaft.
13 Clean all traces of dirt from the area
around the oil seal aperture then apply a
smear of grease to the outer edge and lip of
the new oil seal.
14 Making sure its sealing lip is facing
inwards, slide the new seal along the selector
shaft and tap it squarely into position, using a
suitable tubular drift (such as a socket) which
bears only on the hard outer edge of the seal.
15 Refit the selector lever position switch as
described in Section 8.
7 Fluid cooler general information
1 The transmission fluid cooler is an integral
part of the radiator assembly. Refer to
Chapter 3 for removal and refitting details, if
the cooler is damaged the complete radiator
assembly must be renewed.
8 Transmission control system
electrical components removal and refitting
4
Selector lever position switch
1 The switch is a multi-function switch,
performing the reversing light and starter
inhibitor switch functions as well as operating
the selector lever position indicator panel. If at
any time the indicator panel or reversing light
operation becomes faulty, or it is noted that
the engine can be started with the selector
Automatic transmission 7B•5
lever in any position other than P (park) or N
(neutral), then it is likely that the switch is
faulty. If adjustment fails to correct the fault
then the switch assembly must be renewed.
Removal
2 Position the selector lever in the N (neutral)
position. Firmly apply the handbrake then jack
up the rear of the vehicle and support it on
axle stands.
3 Referring to Chapter 4A, slacken and
remove the bolts securing the front pipe/
catalytic converter to the intermediate pipe and
separate the flange joint; on 2.5 and 3.0 litre
models disconnect both left- and right-hand
sides. Unbolt the heatshield(s) from the vehicle
underbody to gain access to the propeller shaft
centre bearing.
4 Slacken and remove the two bolts securing
the propeller shaft centre bearing bracket to
the vehicle body (see Chapter 8). Recover any
washers (where fitted) which are positioned
between the bracket and vehicle body.
5 Trace the wiring back from the switch and
disconnect it at the wiring connector. Unclip
the wiring connector from the side of the
transmission housing so that it is free to be
removed with the switch. If the connector
retaining clip is broken on removal, obtain a
new one for refitting.
6 Unclip the protective cover from the switch
then unscrew the retaining nut and free the
selector lever from the end of the transmission
shaft (see illustrations).
7 Place a jack with a block of wood beneath
the transmission, and raise the jack to take
the weight of the transmission.
8 With the transmission securely supported,
slacken and remove the bolts securing the
transmission unit rear mounting crossmember
to the vehicle body.
9 Lower the transmission slightly until access
can be gained to the switch retaining bolts. As
the transmission is lowered, take great care to
ensure excess strain is not placed on the
propeller shaft or any of the engine
components and enlist the help of an
assistant to make sure nothing becomes
trapped between the rear of the engine and
bulkhead. Note: On 2.0 litre SOHC engines it
maybe necessary to remove the DIS module
assembly to gain the necessary clearance
required (see Chapter 5B).
10 Slacken and remove the retaining bolts
and slide the switch off of the selector shaft.
Whilst the switch is removed check the shaft
oil seal for signs of leakage and renew if
necessary (see Section 6).
Refitting
11 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 backwards (to the P
position) then move it two notches forwards.
12 If a new switch is being fitted, locate the
switch on the shaft then refit the retaining
8.6a Unclip the protective cover from the
position switch . . .
8.6b . . . then slacken and remove the
retaining nut (arrowed) and free the
selector lever from the shaft
bolts, tightening them to the specified torque.
Note that it is not necessary to adjust the
switch since it is set at the factory and sealed
in position; the seal will be broken the first
time the selector lever is moved.
13 If the original switch is being refitting,
locate the switch on the transmission shaft
then refit the retaining bolts. Adjust the switch
as described in paragraph 21 before tightening
the retaining bolts to the specified torque.
14 Reconnect the selector lever to the
transmission shaft then refit the retaining nut.
Tighten the nut to the specified torque setting
then clip the protective cover back onto the
switch.
15 Securely reconnect the wiring connector
then clip the switch connector back onto the
transmission unit and raise the transmission
unit back up into position.
16 Remove all traces of locking compound
from the transmission unit rear mounting
crossmember to body bolt threads. Apply a few
drops of thread locking compound (Vauxhall
recommend the use of locking compound
15 10 181 - available from your Vauxhall dealer)
to the threads of each bolt then refit the bolts
and tighten to the specified torque.
17 Align the propeller shaft centre bearing
bracket with the body making sure any
necessary washers (where fitted) are
positioned between the bracket and body.
Refit the bracket retaining bolts and tighten to
the specified torque.
18 Referring to Chapter 4A, refit the heatshields and reconnect the exhaust system
flange joint(s) then lower the vehicle to the
ground.
21 With the transmission in neutral, the slot on
the switch body should be correctly aligned
with the slot on the switch inner ring. Check this
by inserting the welding rod (see illustration). If
adjustment is necessary, slacken the switch
retaining bolts and rotate the switch assembly
as necessary before retightening the bolts to
the specified torque setting.
22 Refit the selector lever to the shaft and
tighten its retaining nut to the specified torque.
23 Clip the protective cover back onto the
switch then lower the vehicle to the ground.
Sport mode switch
Note: A soldering iron and solder will be
required to renew the switch.
Removal
24 Unclip the selector lever gaiter from the
centre console.
25 Push the switch out of the top of the
selector lever by inserting a length of welding
rod up through the selector lever bore.
26 Make identification marks between the
switch and wires then carefully unsolder the
wires from the switch terminals and remove
the switch.
Refitting
27 Solder the wires to the terminals of the
switch, using the marks made prior to removal
to ensure they are correctly connected.
7B
Adjustment
Note: Before adjusting the switch first ensure
the selector linkage is correctly adjusted (see
Section 3). A short length of welding rod with
a diameter of 2.0 to 2.3 mm will be required
for adjustment.
19 Position the selector lever in the N
(neutral) position. Firmly apply the handbrake
then jack up the rear of the vehicle and
support it on axle stands.
20 Unclip the protective cover from the
switch then unscrew the retaining nut and free
the selector lever from the end of the
transmission shaft.
3510 Vauxhall/Opel Omega
8.21 Adjusting the selector lever position
switch
1 Switch retaining
bolts
2 Switch grooves
3 Welding rod
7B•6 Automatic transmission
connector then carefully free the ignition key
switch wiring from the rear of the connector.
Disconnect the switch earth lead from the
lever mounting plate.
43 Prise off the retaining clips and remove
the switch from the vehicle (see illustration).
Refitting
44 Refitting is the reverse of removal using
new retaining clips.
Electronic control unit (ECU)
Removal
8.30 Removing the winter mode switch
panel from the centre console
8.35 Selector lever pawl switch later models
28 Push the switch securely into position
then clip the selector lever gaiter back onto
the console.
Winter mode switch
from the around the selector lever.
35 Disconnect the wiring connectors then
prise off the retaining clips and remove the
switch from the selector lever mounting plate
(see illustration).
Removal
Refitting
29 Unclip the selector lever gaiter from the
centre console.
30 Reach in behind the console and push the
switch panel out of position, disconnecting its
wiring connector as it becomes accessible
(see illustration). The switch and panel can
then be separated.
36 Refitting is the reverse of removal
ensuring the switch is securely retained by the
new clips.
Refitting
37 Remove the selector lever as described in
Section 5 (see illustration).
38 Disconnect the solenoid earth lead from
the lever mounting plate and carefully free the
solenoid wiring from the main wiring
connector.
39 Undo the retaining screws and remove
the solenoid from the lever mounting plate.
31 Refitting is the reverse of removal
ensuring the wiring is correctly routed.
Kickdown switch
32 The kickdown switch is an integral part of
the accelerator cable and cannot be renewed
separately. Refer to Chapter 4A for details of
accelerator cable removal and refitting.
Selector lever pawl contact
switch - later models
Note: New switch retaining clips should be
used on refitting.
Removal
Selector lever pawl starter
solenoid - later models
Removal
Refitting
40 Refitting is the reverse of removal making
sure the solenoid is correctly engaged with
the pawl.
Ignition key release contact
switch - later models
45 The ECU is located behind the right-hand
side of the facia. Prior to removal, disconnect
the battery negative terminal.
46 On right-hand drive models, release the
retaining clips (rotate them through 90º) then
remove the undercover panel from the drivers’
side of the facia. Remove the fastener (prise
out the centre pin then pull out the fastener
outer section) then unclip and remove the
heater/ventilation duct.
47 On left-hand drive models remove the
glovebox (see Chapter 11).
48 On all models, unscrew the retaining nuts
securing the ECU to the pillar then carefully
lower the ECU out of position. Release the
retaining clip and disconnect the wiring
connector then remove the ECU from the
vehicle.
Refitting
49 Refitting is the reverse of removal
ensuring that the wiring is securely
reconnected. If a brand new ECU has been
fitted it will be necessary to take the vehicle to
a Vauxhall dealer to have the unit coded to
match the performance of the relevant engine
fitted to your vehicle.
Transmission output shaft speed
sensor
Removal
33 Remove the centre console as described
in Chapter 11 then position the selector lever
in the P (park) position.
34 Slacken and remove the retaining nuts
and bolt then remove the front and rear
support brackets from the rear heater/
ventilation duct. Unclip the duct and remove it
Note: New switch retaining clips should be
used on refitting.
41 Carry out the operations described in
paragraphs 33 and 34.
42 Disconnect the selector lever main wiring
50 The output shaft speed sensor is fitted to
the rear of the transmission unit where it is
located above and to the left off the propeller
shaft flange (see illustration).
51 To gain access to the sensor, firmly apply
the handbrake then jack up the front of the
vehicle and support it on axle stands.
52 Disconnect the wiring connector and wipe
8.37 Selector lever pawl starter solenoid later models
8.43 Ignition key release contact switch later models
8.50 Transmission output shaft speed
sensor location
Removal
3510 Vauxhall/Opel Omega
Automatic transmission 7B•7
9.3 Slide off the retaining clip and detach
the selector linkage rod from the
transmission
clean the area around the sensor.
53 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
54 Fit the new sealing ring to the sensor
groove and lubricate it with a smear of
transmission fluid.
55 Ease the sensor into position then refit the
retaining bolt and tighten it to the specified
torque setting. Reconnect the wiring
connector then lower the vehicle to the
ground.
Transmission solenoid valves
56 Removal and refitting of the various
solenoid valves should be entrusted to a
Vauxhall dealer.
9 Automatic transmission removal and refitting
4
Removal
1 Chock the rear wheels, apply the
handbrake, and place the selector lever in the
N (neutral) position. Jack up the front of the
vehicle, and securely support it on axle
stands. Undo the retaining screws and
remove the undercover from beneath the
engine unit. Disconnect the battery negative
terminal. Note: On models with a Vauxhall
anti-theft warning system (ATWS), the battery
negative terminal must be disconnected within
15 seconds of the ignition being switched off
to prevent the alarm system being triggered.
2 Working as described in Chapter 8, unbolt
the front end of the propeller shaft from the
transmission flange and remove the vibration
damper (where fitted). Position the propeller
shaft to the right of the transmission unit and
tie it to the vehicle underbody.
3 Slide off the retaining clips and detach the
selector linkage rod from the transmission unit
and selector lever and remove it from the
vehicle (see illustration). Take care not to
lose the lever pivot bushes.
4 Trace the fluid cooler pipes back from the
transmission unit to their flexible hoses.
9.4a Release the retaining clips and
disconnect the oil cooler pipes . . .
9.4b . . . then fold them back and connect
them as shown to minimise fluid loss
Remove all traces of dirt then slacken the
retaining clips and disconnect both hoses.
Minimise fluid loss by folding each hose back
on itself and securely connecting it to its
adjacent pipe (see illustrations).
5 Disconnect the wiring connector from the
output shaft speed sensor (see illustration
8.50), which is located at the rear of the
transmission unit, and free the wiring from the
transmission unit.
6 On SOHC engines, disconnect the wiring
connector from the DIS module (see Chapter 5B). Slacken and remove the module
mounting bracket retaining bolts, noting the
correct fitted location of the engine lifting
bracket, then free the wiring harness and
remove the module and bracket from the rear
of the cylinder head. Free the HT leads from
their retaining clips and position the assembly
clear of the transmission unit.
7 On all models unclip the oxygen sensor
wiring connector from transmission unit and
disconnect it.
8 Slacken and remove the exhaust system
front pipe mounting bracket bolt then remove
the bolts securing the front pipe to the
intermediate pipe and separate the two
exhaust sections.
9 On models with a one-piece engine sump,
slacken and remove the bolts securing the
support brackets to the transmission housing
and sides of the cylinder block. Remove both
brackets from the engine then remove the
torque converter lower cover plate from the
base of the transmission housing.
10 On models with a two-piece engine sump,
remove the cover from the sump flange to
gain access to the torque converter to
driveplate bolts.
11 Slacken and remove the visible bolt(s) then,
using a socket and extension bar to rotate the
crankshaft pulley, undo the remaining bolts
securing the torque converter to the driveplate
as they become accessible; there are six bolts
in total. If necessary, to prevent rotation as the
bolts are slackened, remove the cover from the
base of the torque converter housing and retain
the driveplate by inserting a large screwdriver
in through the hole.
12 Place a jack with a block of wood beneath
the transmission, and raise the jack to take the
weight of the transmission (see illustration).
13 With the transmission securely supported,
slacken and remove the bolts securing the
transmission unit rear mounting crossmember
to the vehicle body (see illustration).
14 Lower the transmission unit slightly and
disconnect the vent hose from the top of the
transmission housing.
15 Trace the wiring back from the selector
lever position switch and disconnect it at the
wiring connector. Unclip the wiring connector
and position it clear of the transmission
housing; if the connector retaining clip is
broken on removal, obtain a new one for
refitting.
16 Release the retaining clips and disconnect
the wiring connectors from the side of the
transmission main and intermediate housings
(see illustration). Release all the wiring from
its retaining clips, noting its correct routing,
and position it clear of the transmission unit.
9.12 Securely support the transmission
unit with a suitable jack . . .
9.13 . . . then slacken and remove the
bolts securing the transmission unit
crossmember to the body
2.0 litre engines
3510 Vauxhall/Opel Omega
7B
7B•8 Automatic transmission
9.16 Disconnect the wiring connectors
from the transmission unit and free the
wiring from its retaining clips
17 Slacken and remove all the bolts securing
the transmission housing to the engine. Note
the correct fitted positions of each bolt, and
the necessary brackets, as they are removed,
to use as a reference on refitting. Make a final
check that all components have been
disconnected, and are positioned clear of the
transmission so that they will not hinder the
removal procedure.
18 To ensure that the torque converter does
not fall out as the transmission is removed,
slide the converter along the shaft and fully
into the transmission housing.
19 Move the trolley jack and transmission to
the rear, to free it from its locating dowels.
Once the transmission is free, carefully lower
the jack and manoeuvre the unit out from
under the vehicle. Remove the locating
dowels from the transmission or engine if they
are loose, and keep them in a safe place.
2.5 and 3.0 litre models
20 Remove both the exhaust system front
pipes as described in Chapter 4A.
21 Remove the cover from the sump flange
to gain access to the torque converter
retaining bolts. Slacken and remove the
visible bolt then, using a socket and extension
bar to rotate the crankshaft pulley, undo the
remaining bolts securing the torque converter
to the driveplate as they become accessible;
there are six bolts in total. If necessary, to
prevent rotation as the bolts are slackened,
remove the cover from the base of the torque
converter housing and retain the driveplate by
inserting a large screwdriver in through the
hole (see illustrations).
9.21c If necessary, the driveplate can be
retained by removing the cover and inserting
a large screwdriver in through the hole
9.21a Prise out the cover from the sump
flange . . .
22 Remove the transmission as described in
paragraphs 12 to 19.
Refitting
23 The transmission is refitted by a reversal
of the removal procedure, bearing in mind the
following points.
a) If a new transmission unit is being
installed, drain the fluid cooler and blow
out the cooler lines using low-pressure
compressed air.
b) Check the torque converter centering pin
and the crankshaft bush for signs of wear
or damage. Remove all traces of dirt and
rust then lubricate the bush a pin with a
thin smear of molybdenum disulphide
grease (Vauxhall recommend the use of
lubricating grease 19 48 568 - available
from your Vauxhall dealer).
c) Prior to refitting, ensure that the torque
converter is correctly engaged with the
transmission by measuring the distance
from the converter driveplate bolt lugs to
the transmission mating surface. This
should be 15 mm (see illustration).
d) Ensure the locating dowels are correctly
positioned and take great care not to
allow the weight of the unit to hang on the
torque converter as it is installed. Once
the transmission and engine are correctly
joined, refit the securing bolts, tightening
them to the specified torque setting.
e) Align the torque converter with the
driveplate then refit the retaining bolts
tightening them lightly only to start then
go around and tighten them to the
specified torque setting in a diagonal
sequence.
f) Ensure that the transmission wiring/hoses
are correctly routed and retained by all
the necessary clips.
g) Remove all traces of locking compound
from the transmission unit rear mounting
crossmember to body bolt threads. Apply
a few drops of thread locking compound
(Vauxhall recommend the use of locking
compound 15 10 181 - available from
your Vauxhall dealer) to the threads of
each bolt prior to refitting and tighten
both bolts to the specified torque.
h) Tighten all nuts and bolts to the specified
torque (where given).
3510 Vauxhall/Opel Omega
9.21b . . . then slacken and remove the
torque converter to driveplate bolts as
described in text
i) On completion, refill the transmission with
the specified type and quantity of fluid as
described in Section 2 and adjust the
selector linkage as described in Section 3.
10 Automatic transmission
overhaul general information
5
1 Overhaul of an automatic transmission unit
is beyond the scope of the home mechanic
and should be entrusted to a transmission
specialist.
2 In the event of a fault occurring with the
transmission, the vehicle should be taken to a
suitably-equipped Vauxhall dealer for testing.
A wiring block connector is incorporated in
the electronic control circuit, into which a
special electronic diagnostic tester can be
plugged (see Section 1) and this should locate
the fault.
3 Do not remove the transmission from the
car for possible repair before professional
fault diagnosis has been carried out, since
most tests require the transmission to be in
the vehicle.
9.23 Check the torque converter is fully
engaged by measuring the distance (X)
from the converter bolt lugs to the
transmission surface. This should be 15 mm