Opel Astra Clutch Replacement - Without Gearbox Removal
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- Опубликовано: 24 авг 2024
- Check out my website www.vehiclemai...
This video shows how to replace a clutch assembly on an Opel Astra 1994, without removing the gearbox, it is a simple operation, but requires special clips to hold the pressure plate in a charged/depressed state, while removing the old and fitting the new.
Enjoy the video and please subscribe to help improve the channel, until my next video, safe motoring.
Gary
Thanks so much for posting this video. I was able to change the clutch on my driveway for under £50! Couldn't have done it without your guidance.
@@vehiclemaintenanceandrepai3790 Can I ask a question... Although the clutch is working great I've got a significant gearbox oil leak but it's coming from behind the clutch cover plate. I took it off and that's definitely the source. I did top the gearbox up after I changed the clutch but only to the level of the grub screw.
Is it possible I've dislodged a seal when I put the transfer shaft back? Or just overfilled it somehow?
@@vehiclemaintenanceandrepai3790 Thanks so much for getting back to me. If there was a preexisting leak it would explain why the gearbox took nearly a litre of oil when I 'topped it up'. Sounds like I'm getting a bit out of my depth now so it might be time to give up and get mechanic to have a look! Thanks again for all your help.
This is an awesome video. I drive a Zafira with the extra heavy flywheel - what a mission to replace the clutch or have the CSC replaced. So I converted to the Astra lighter flywheel, fork, and fabricated an external hydraulic slave with a custom-made bracket mounted to the gearbox. Also fitted an aftermarket master and slave cylinder with new clutch lines. Added a longer push shaft to the thrust bearing to compensate for extra throw. Will share pics once I have the throw-out point and release pressure figured out. Advice/comments welcome.
if you are not a mechnic, go to one, save some money...
The last time I changed a clutch like that was on my mk2 cavalier. About 20 years ago, got me remonising now 🙂👍thanks.
Wow, that was a while back, thanks for supporting my channel with your visit, feel free to share if there are any tips to make this job easier.
me too.
Thanks for posting this video!
Very much appreciated!
Repairing my old german built 1998 Opel
Combo ( called in Australia Holden Combo) with 180000km.
Has been so far a super reliable and simple "old school" car with great fuel economy and usefull loading ability! Worthwhile keeping and maintaining!
Thanks for the video again and blessings.
Karl, from Tasmania
Thanks For supporting my channel with your visit and interaction, Karl, it does me good to see my efforts appreciated by my viewers, this is why I do these videos to help you folks out there.
Hey Karl, how did it go? My 2004 Holden Astra just shat itself and isn’t moving an inch no matter what gear I’m in. I’m thinking about trying this, but I’m wondering are these Opels and Vaxhaulls the exact same as Holdens?
(Also, according to Wikipedia, my model was actually made in Poland, while the 2004 hatchbacks were made in Belgium).
It’s all hard to work on, specialty tool requiring euro trash to me. With I had a 202 kingswood. I could switch out an engine blindfolded on that. These euro cars suck to work on.
@@davidprice7162 they suck cause you dont know how to work on them,,, and they need a lot of work,,
A man with a plan thank you for the help I have a 96 model Astra F I will be doing my own clutch in time to come
Thanks for supporting my channel here Tyrone wishing you luck with that.
Definitely designed by someone who actually gets their hands dirty. Fair play to the design team.
Agreed, the design engineers got it right with this one.
Thank You for supporting my channel with your visit and interaction, I am pleased this video was helpful to you.
Please feel free to check out the rest of my channel by clicking PLAYLISTS www.youtube.com/@vehiclemaintenanceandrepai3790/playlists for more helpful service and repair videos on most makes of cars available here in SOUTH AFRICA,
It is FREE.
Very nice and technically explained! He has an Astra F from 93 with 210,000 km and the clutch still doesn't give me any problems; but the future is unknown. The problem would be with the pressure plate blocking parts...let's see what they are made of; a steel sheet would be needed (a sheet that I can iron after bending to the required height).
Sounds about right
Thank You for supporting my channel with your visit and interaction, I am pleased this video was helpful to you.
Please feel free to check out the rest of my channel by clicking PLAYLISTS www.youtube.com/@vehiclemaintenanceandrepai3790/playlists for more helpful service and repair videos on most makes of cars available here in SOUTH AFRICA,
It is FREE.
I love this guy's pronounciation of the word shaft. Shawft. I love it and this video of course
Spent hours with a mate trying to take the gearbox out of my Cavalier GSi 4x4. Someone in the workshop then pointed out this plate !
this is pure gold!! well done sir
many years ago I was told the this acces opening in the transmission was removed to have better noise / vibration/comfort parameters… I think it was cancelled to fill the bank account of the dealers / shops
Those would have been some of the reason. But the main reason will have been manufacturing costs. It would have been cheaper to manufacture a gearbox that doesn't have the plate and sliding input shaft. It's manufacturing cost that affect cars design the most. That's how some brilliant designs for servicing and repairs have been dropped. And mechanics end up with simple jobs that took minutes now take half a day.
Now THIS is is how transverse gearboxes should be designed; Instead of having to pull out half of the components of the engine bay, just a couple plates and some bits and you have the clutch ready to pull off the flywheel.
It's a real shame almost no one else designed gearboxes the same way, SAAB did something like this in the 900/93 classics, and Datsun in the 100A, But as far as I know, no one else is doing this anymore.
It is a shame that not all manufacturers made it so easy, Johnny
Great design! Shame GM took over and completely went backwards for the service guy!
GM bought Opel in the 20s, the car is newer. But i also find it sad that this kind of repair is not possible with newer Cars.
Nothing to do with GM, however the flywheel design changes in the mid 90s to a flywheel with outer rim, preventing the clips from being fitted.
My 1991 cavalier 2.0 was like the video and it cost £84 ( in 1997) to have a new clutch fitted. After about 1992ish, the later flywheel was fitted, meaning it's a gearbox out job
Hoenervleis... If only they kept this design for the Astra H as well...thanks a lot Oom...
Hi I've just subscribed, I haven't had to change a clutch like that in years. The last clutch I had to do like that was on a mk2 cavalier was so much easier/ straight forward thanks Darran
I remember this type of clutch renewal, I had an Astra 1.6 petrol Estate [same unit as the Cavalier] wish all clutches were as easy. I still have the three clips in my garage.
Yes all true, those clips are so hard to find now, Terrance
Great video! I'd love to come over one day and find a Opel Kadet superboss to bring back to the UK
Great car, not easy to find, but I am sure there are a few around still.
For anyone wondering (in 2023) where these clips can be found, it seems that GEDORE / KLANN still sell them, with the part number KL-0401-2010. I haven't bought them as I don't need to replace my clutch (and can't confirm whether they fit or not) but all the images/data available seem to sugest that they do. I might try and order them, just in case.
Thank you for the video, it was very insightful. I had noticed the access port on the gearbox, but wouldn't have imagined they left it there by design, to allow for easier clutch changes. Now I know. I wish more cars were designed with ease of serviceability in mind, but alas, they are not.
Best regards.
Hi Nuno, I cannot thank you enough for your response here as we were getting plenty of queries about the availability of these clips, thanks for supporting my channel with your visit and interaction it is very well received and appreciated.
Gary❤
Those were the days of screwdrivers (training as a car mechanic 94-98) ...
brought my Berlingo B9 to the workshop today ... release bearing defective ... wheels off > loosen suspension > drive shafts out > battery out > entire gearbox > change clutch and release bearing ... calculated expenditure of time: 6-8h ... calculated costs: 1,100€-1,200€ ... exchange however only in the "complete package" ...
Some are easy others are not, Thanks for sharing, and thanks for supporting my channel with your visit.
very intelligently designed, you don't have to disassemble and remove the whole engine

Correct it is genius.
Thank You for supporting my channel with your visit and interaction, I am pleased this video was helpful to you.
Please feel free to check out the rest of my channel by clicking PLAYLISTS www.youtube.com/@vehiclemaintenanceandrepai3790/playlists for more helpful service and repair videos on most makes of cars available here in SOUTH AFRICA,
It is FREE.
I am shure you from cape Town south africa
Awesome! Got a Corsa B with the same type of gear box.
Great, makes replacing a clutch so much easier.
I did it. Thanks from Poland.
Thanks for the support Krystian, I am glad you found the video useful. Gary
Yeah great video and camera work !
What’s the first cable you’re disconnecting? I assumed it was the clutch cable, but you’re tell Giuseppe to press the clutch down later on, so it can’t be that right?
It's well planned and constructed.
Very much so, it would be cool if more car makers used this concept, Robert
Those were the days when they had inspection covers, our old work combo van mark 1s had those covers, they did away with them in the later vauxhall cars, had the same cover on my astra 1.7d too, shame as they were helpfull especially if you had a stiff bearing or inspecting the condition of the cluch
Agreed it was very convenient and cost-saving.
Thank you very much for your video! Please, could you tell if it is possible to do this procedure on an X17DTL engine? My car is a 1995 year diesel ASTRA. I wish I could have found your site sooner.
you are genius
Thanks for the support Bassaam, nice to see my efforts are appreciated by you.
check out my website
www.vehiclemaintenanceandrepairs.com/
awesome video thank you very much.
just wondering if the fly would be able to be removed in this process as well?
thank you again for this video look forward to more
Thanks for visiting my channel and your question to which the answer is a most definitely yes, I did remove a flywheel once to replace the rear engine oil seal.
@@techandoutdoor7301 awesome thank you for your reply
Wonderful job. I need to change a opel Astra F 1994 Combi 1.6i ‘s clutch and these tutorial will help. Unfortunately I can’t find and buy clips , so could you share it dimensions of it? I will DIY them using old pieces of metal. With more questions can I ask you…?
height 20mm, width 18mm , length 22mm
Thank You for supporting my channel with your visit and interaction, I am pleased this video was helpful to you.
Please feel free to check out the rest of my channel by clicking PLAYLISTS www.youtube.com/@vehiclemaintenanceandrepai3790/playlists for more helpful service and repair videos on most makes of cars available here in SOUTH AFRICA,
It is FREE.
I got stuck to the clamp-clips usage.I tapped them but there are still tension - contact point between parts I is not moving freely after taking out the bolts. I may need to adjust size between clamps opposite walls and add more pressure to the plates. Different cars maybe different wear off . Could you share the distance between the walls…?I am getting closer but have some issues. Thanks in advances. Others steps took me 30 minutes.
All reference I have to this job is the video sorry man.
To see if you can change a clutch on Opel/vauxhall cars just look at the gearbox for that inspection plate. When I worked for the dealer we timed the mechanic to change a clutch and it took him just over 10 minutes. Oh always replace the 5th gear cover gasket as sealer will clog up the gear.
Thanks for your support and insights, Ghost Rider666, it is greatly appreciated. Gary
hi there nice video ..where can i get this clips for the clutch .. thanks michael
I bought mine at a local Parts Store here in Cape Town many years ago best to do a google search, it may produce results.
Amazing tutorial, thanks for sharing
Thanks for the support.
Would this procedure work for an Astra 'G' (Mk4 ) pressure and friction plate ? Probably wouldn't be able to do the thrust bearing as the Mk4 has a CSC.
Brilliant! - Thank you!
Thanks for supporting my channel with your visit Lee, I am glad you liked the video.
What is the target tool for clutch mounting? Do not push the spring!
Hi, sorry, I do not fully understand your question !!!
Is this the same procedure for an opel corsa b model??. I have a 1995 diesel corsa and sounds like the thrust/throwout bearing is squealy/noisy when cold--clutch seems to engage ok and no slipping though. Pretty sure this is similar setup but with a slightly different gearbox (F13) , great video. thanks
Hi Geoff, thanks for your support, the best way to check is go underneath the gearbox and see if your Opel has the 4 bolt inspection plate, if so the procedure is the same, if not the gearbox must be removed.
@@vehiclemaintenanceandrepai3790 Have had a look and its exactly the same! Guess when it comes to replacing the clutch it wont be a gearbox out job phew!!
And can you make a video our to change the clutch and pressure plate of opel astra G 1.8 pls
When one comes in I will make the video, thanks for your support.
excellent man..!
Thanks for video!
It is a pleasure Daniel, this is why I make these videos, thanks for supporting my channel with your visit.
Gary
Can this be done on a Corsa C Gamma?
*Very Good!*
Very good! Thank you sir!
Thanks for your support Ernesto, wishing you an awesome 2021
I have one Opel astra A-H 1.6 automatic car ,last few months I am getting one problem,when I drive slowly car engine stop again and again ,I need answers plz
You are giving too little info, sorry.
Thank You for supporting my channel with your visit and interaction, please feel free to check out the rest of the channel by clicking PLAYLISTS www.youtube.com/@vehiclemaintenanceandrepai3790/playlists for more helpful service and repair videos on most makes of cars available here in SOUTH AFRICA.
Dag se oom kan mens die flywheel ook so uit haal? Om crank seal te vervang?
Ja dit kan gedoen word ek het, Anton
Sir could you please help me with the fan belt size for a 1996 opel astra 1.4 8v si sedan. C14se engine. I cannot manage to find the size.
i just wanted to know why you have to use the clips?? what if i don't use it? please let me know ASAP
The job cannot be done without the clips the pressure plate needs to be charged when removed and fitted as the unit will not fit in the restricted inspection hole. Without the clips the pressure plate is too wide/high/thick.
Super helpful... thanks
Does this method works on Opel Astra F 1993, C14NZ engine model? I tried to pull that shaft with a M7 bolt, even with a lever to have more strength, but nothing happened. I really need to change my clutch disk asap. Thank you in advance for your answers.
Hello, i’ve astra j sporttourer 1.7 110 cv.
Please which part?
Luk, Valeo, Sachs?
Luk or Sachs, I never successfully ever used a Valeo.
Thank You for supporting my channel with your visit and interaction, I am pleased this video was helpful to you.
Please feel free to check out the rest of my channel by clicking PLAYLISTS www.youtube.com/@vehiclemaintenanceandrepai3790/playlists for more helpful service and repair videos on most makes of cars available here in SOUTH AFRICA,
It is FREE.
Hell why the new cars haven't hole like this
thanks a lot for the video
hi my name is craig i recently replaced my gearbox and thrust bearing but when i placed the clutch cable back the clutch pedle was almost against the dashboard any advice the possition of the thrustbearing fork ?
Hi! Something is not right, because if you put everything in place, it should be good.
@@vehiclemaintenanceandrepai3790 ty i did that now my clutch is fine
excellent. can I do it in my car? my car opel vectra A 1995 gl and F18 gearbox ?
Just look at the gearbox from below, if you've got that plate you can. If not you'll have to remove the gearbox.
hello I'm driving a Opel kadett 200is 98'' 16v but I am using Opel kadett GSI 200 95'' 16v Superboss engine motor. I need to replace Clutch kit what size my I use & how may teeth size must I use.
Hi Sphiwe, thanks for supporting my channel with your visit, since you modified this car it is best to take a sample after you stripped it to get the correct clutch, hope this helps. Gary
Will this method work on a opel kaddet 160i
The only way to be sure is to check if the bell housing has the inspection plate which can be removed by loosening the 4 bolts that hold it down, if it does not have the inspection plate then no.
Dankie Oom
Dit is 'n plesier Cobus,
Hi, where can I get a set of those clips ??
Hi, why opel service manual doesn't mention this method of changing the clutch, speedier than having to detach the gear box from the engine? Isn't it dangerous unscrew the input shaft?
No Valerio, it is not dangerous to unscrew the input shaft, this is how some models of these Opel were designed.
I've just a problem, the bolt of the shaft is it an M7 xzn type? Because i've tried with M6 and M8 and they're not right, and i found that it isn't a Torx bolt but an XZN bolt
yes it is M7
Is this the same for opel astra 2005 cdx please
The only way to tell is to look under the car at the gearbox bell housing which houses the clutch to see if there is a removable inspection plate with 4 bolts, if not the gearbox must be removed, Tanille.
انت عبقري
Wow..he actually did with out removing the gearbox 🤯🤯🤯hahah
Yes, I did Hahaha as promised in the video.
Excellent! Did you skim the flywheel? Is it required? Can you remove the flywheel this way? Where can I get those pressure plate clips? Where are you based?
Are the clips handmade? Where would you be able to get them?
The clips should come with the new clutch assembly. But you could buy them from the main dealer or a motor factors
I know about the clutch change that is really easy. I just want to know your opinion. I had the bigger Astra flywheel in my 2.0 16v Kadett/Monza also known as the Mk2 Astra/Belmont. I switched up to the old Superboss or first red top flywheel. You can feel the power difference because of the weight. The car Rev up more quickly which is expected but I want to know is which one you will choose and why. I feel that the car will be more economic because it takes less to Rev up the engine. The engine also feels happier. Do you think I made a mistake by changing back to the old setup? I personally feel that in the long run it would be better but it is my point of view.
Hi Willem, thanks for supporting my channel with your visit and interaction, my answer to this is, I am a traditional old school mechanic who does not believe in conversions, I believe when something is engineered a certain way there is always a good reason for it, but if the change works for you then why not, as long as there is no long term damage, I guess only time will tell.
@@vehiclemaintenanceandrepai3790 I do support good channels on RUclips and was glad to see you giving people some good advice. The problem I have was that the car had a Astra flywheel in but it did not came with the old Monzas as you have shown in your video on how to remove the clutch without dropping the gearbox
Well my car was supposed to work the same way but with the Astra flywheel it was impossible. I then removed the Astra flywheel and put a Monza one back to make the car original and so that I can change the clutch without taking out the gearbox like in your video. I was more curious on why someone would fit a Astra flywheel on this car because I couldn't feel any torque difference and the car actually feels more lively back in its original state.. I thought that maybe a Astra clutch lives longer than a Monza one but it doesn't make any sense. To me a clutch is a clutch as long as it is a good brand. I am more curious as to why they converted it back then
Maybe it was just an experiment on their part to see what would happen by changing the flywheel, as I said earlier, I do not believe in conversions unless it is brought about by the manufacturers as an upgrade.
Never used the clips tbh 😊
So how did you do it?
I've got a 1995 vauxhall cavalier I got the clutch replaced but a day after driving the car it wasn't select ing gear only selected gear when the gear stick was forced in , had the clutch cable adjusted abit and it's still the same ??
@@vehiclemaintenanceandrepai3790 the clutch went and the car wouldn't select gear got new clutch kit fitted (looking at the old clutch it was in bits) was smooth after a day then it wouldn't really select gear only when forced in , got the cable adjusted still sort of the same , but it was never like that before the new clutch , just really want to no what it could be ?
@@vehiclemaintenanceandrepai3790 no I haven't got the flywheel replace there was no work done to the flywheel at all , cars a 1.8i petrol , I will do what you said so put the car in 1st gear take foot of clutch and start it up ? Thanks
Why this was abandoned as a design I'm baffled probably cost.
As we know in the industry when something works well and lasts, it will be discontinued to make way for something that makes more money.
On the way watch this space as I am busy with all the requests.
Thank You for supporting my channel with your visit and interaction, I am pleased this video was helpful to you.
Please feel free to check out the rest of my channel by clicking PLAYLISTS www.youtube.com/@vehiclemaintenanceandrepai3790/playlists for more helpful service and repair videos on most makes of cars available here in SOUTH AFRICA,
It is FREE.
What are the dimensions of these metal clamps?
Can you measure them?
It is about an inch in width, length and height, as a hollow cube.
Thanks for the answer, greetings from Serbia👍
When vauxhalls where a easy car to work on
Thanks for the support Tigerman, they certainly were at the time.
Hey man I'm from Cape Town. Could this be done on a Astra opc? 2008
@@vehiclemaintenanceandrepai3790 thanks man. It's such a mission!! I will leave that for another day. Awesome vid by the way
sorry I want to ask about my gear shift gear 1995 opel astra sohc. when the condition of the engine is hot ... the gear is suddenly difficult. sometimes for example reverse gear can 12345 gear can't and if 12345 teeth can replace reverse gear can't ... can it be repaired without having to replace the gearbox ?? bearing in mind that in Indonesia it is hard to find a workshop that is good at opels and spare parts
@@vehiclemaintenanceandrepai3790 thank you very much bro
@@vehiclemaintenanceandrepai3790whether the gearbox oil and engine oil are separated or combined. gearbox oil should be how thick the thickness is, and how thick is the engine oil boss ???
oil change
like this video
Thanks for supporting my channel, Joseph, it is much appreciated. Gary
compression staples where did you get them?
Hi Alberto, I acquired the clips a few years ago but I tried to get some recently, but had no luck so far, maybe a google search will help.
Is this procedure also applicable on a opel astra f 1.7 diesel station wagon 1992 ? Thanks in advance :).
Hello Mathew, thanks for supporting my channel by watching the videos and interacting with me, I doubt if it can be done on that model, best is to take a peek under the gearbox and see if it has that inspection plate which is held by 4 bolts. Visit my website for more useful info and let me know what you think, thanks once again for your support.
www.vehiclemaintenanceandrepairs.com/
@@vehiclemaintenanceandrepai3790 thanks for your reply and for your helpful tips. I will take a look and get back to you.
Hi Gary. Hope you are doing well? I Just wanted to ask, where could one find those clips to keep the pressure plate compressed?
Please and thanks
Where does one get those special clips?
Hi Terence, thanks for supporting my channel with your visit, it is greatly appreciated and helps to build the channel, I tried locating these clips after numerous requests from viewers but was not successful, sorry, please let me know if and when you locate it and I will do the same, all the best ahead.
Gary
Amazing
It really is why other manufacturers or cars do not do this surprises me, Javier
@@vehiclemaintenanceandrepai3790 where I can find those clips? I suppose they can be used in any clutch disks
I have no idea on where to get them separately, when I did this job a while back I got the clips in the clutch kit.
@@vehiclemaintenanceandrepai3790 wich brand is that?
LUK Repco
Does this work on a 2004 Astra Enjoy 1.6 petrol, please. Many thanks. I think it is F17?
if it has the 4 hole inspection plate on the bottom of the gearbox bell housing then , yes.
Gear box F13/5 ?
Thanks for your interaction and support of my channel. Gary
👍👍
bit head m8?
ok
Thanks for your visit and support, Rawaz
Thats ok on older cars
That is so Scott, don't you wish they made newer models the same way, it would be a mechanic's paradise.
Very very old vehicles now, no longer on the road
Hi David yes it is an older car but I see many of it on the road still, running pretty strong too.