transmission removal zafira

ZippyZafira

Hi guys

I have a 2002 Zafira (z22se engine)

I need to pull the transmission out and replace it. Ok was wondering if anyone can give me the basic steps please and any tips

I have pulled many motors out of these cars but never a transmission.

Thanks heaps

vocky

similar to a manual box, but you need to remove the transmission plate bolts via the starter motor hole

ZippyZafira

Never removed manual gearbox either before.

Just need a quick guide where to start.

vocky

you will need to drop the subframe off, remove the driveshafts, remove the three downpipe bolts from the exhaust manifold joint, lower the gearbox side of the engine/box so the gearbox can slide off the engine and clear the chassis, then remove the box.

ZippyZafira

Thanks Vocky

Once again you have come to my rescue

So here is where im at

I have just removed the subframe off (bit of a prick of a job) and now im up to removing the drive shafts.

My question is How do you get the drive shafts out of the transmission? do the just pop out???

I can seem to get mine to move

astra22bertoneauto

vocky said:
you will need to drop the subframe off, remove the driveshafts, remove the three downpipe bolts from the exhaust manifold joint, lower the gearbox side of the engine/box so the gearbox can slide off the engine and clear the chassis, then remove the box.

A quick note; on auto transmission units the engine mount is actually mounted to the gear box at the lower front, so you will need to support the engine as there is only 1 actual mount holding the engine.

I believe its different for a manual box.

ZippyZafira

Ok got the transmission out. Driveshafts eventually popped out.

This has been a real nightmare.

Hopefully I can get it all back together with the new transmission

Looks a mess at the moment.

ZippyZafira

Ok transmission is OUT. Just started on the fun part putting it all back together.
Spent a good part of an hour trying to align the transmission back into the engine but eventually got it.

Damaged the thread on the cv on one of the drive shafts being a idiot "hit it with a hammer to tap it in without the nut on the end, dumb real dumb"
(Anyone know if the passenger side drive shaft is universal to a manual? Or at least just the cv part)

If u can get that sorted I will be up and running again tomorrow.

vocky

the outer cv's are normally dependent on the size of the hub rather than auto or manual, so if you have the same hubs as a manual (quite likely) then they should be the same. The only way to be sure is to count the splines.

ZippyZafira

3 days done and she I is all swapped over. Ended up taking the drive shaft to a metal fabrication place and got the end re-threaded.

Now for the stupid question how do tell when the auto transmission has the correct level of oil? Can't figure out how to read the dip sick