The older Corsa's are blessed with a plastic gear linkage that features ball and socket joints which eventually wear. Setting off and selecting second gear starts playing up at the worst times like roundabouts when you need to pull out quickly. That issue will get worse until 1st and second gear won't go in without significant effort. If you leave this long enough (like my good mate Tim) reverse will not select at all....
Advisable to fix this gear linkage when it first starts to play up and before the ball joints start popping off completely. If a ball joint pops off the gear stick will go floppy and feel disconnected. You can jam some paper over the plastic ball to create a tighter fit and lever the socket back on. If the end ball joints look connected check the plastic link bar on the top of the linkage with the same principle. This is a very temporary bodge to get you home or to the garage though. One comedy drive to mine later where reverse gear stick position was actually 1st!, it was time to crack on.
Genuine GM part (93183155) and pin (90523189) required for this job. If you already have the metal linkage you have the option of buying an aftermarket bush repair kit on eBay. Aftermarket linkages are also available but you might find they result in a stiffer or less accurate gear change. For a hassle free experience I would recommend the genuine part for this job.
This is the part responsible for the problem with the old plastic based linkage on the right. You can see how the design has changed with the larger sockets now underneath and made of metal with plastic sockets. They also have nice plastic shields presumably keeping dirt and moisture from causing wear in the joints.
First job I did was lock the selector rod in position. 5.5mm drill bit worked for me pushing the gear stick left and using the alignment holes.
The gear linkage is at the rear of the engine and undoing the bolt that secures the linkage to the selector rod is probably best accessed from underneath. However my axle stands were in use on another car and I fancied doing the job from above. Knew my long skinny arms would be useful one day!
With the selector rod locked in position and the bolt undone you can separate the selector rod and linkage.
Now I locked the gearbox selector in position by turning it right (reverse gear direction) and pressing in the orange button until it engaged. Press the orange button lightly and turn slowly until you find the right position. The button will press in and remain depressed until you select reverse gear later on.
Next step is removing the pin on the universal joint that has a springy metal retainer built in. I found pressing this in and pushing up will give you enough room to lever it out with a screwdriver.
The gear linkage pivots on a metal rod with a grove around the top. The black plastic retaining cap has 4 wedge clips that locate in this grove and prevent it coming off. Use a screwdriver to snap each of the small clips and then simply lever it off.
Linkage now removed you can see how it attached and ready for refitting.
Install new linkage putting everything roughly in position before you install the black plastic retaining gap. Give it a good pull up to ensure you have that cap on securely.
My new universal joint pin was slightly different to the old one.
As a result of this the new one had slightly more metal protruding from the top. Worth a mention as I was trying to push it in further when it was already at its maximum depth.
Check the gear box selector is still locked in place and now tighten the selector rod clamp bolt. The torque setting for this is 12 Nm + 225° and can be done from the top with a small torque wrench and those skinny arms again.
Nearly done, remove drill bit from gear stick and select reverse gear. Go check this has released the gearbox selector and the orange button should've popped out. With the engine off and clutch in check gear selection feels right then start engine in neutral with clutch depressed. Bring to bite slowly and that first is defiantly wanting to move forward and check reverse. Go for a quick test drive when the roads are quiet and ensure you are happy with the gear selection. This is where I think the genuine part shines and no messing about needed, the alignment was spot on for me with this procedure.
Job done stand back and admire your shiny new gear linkage and confidence in pulling away without embarrassing selection issues.
