Vauxhall Workshop Service and Repair Manuals

Main Shaft, Dismantle and Assemble (F17+)

Note:   Transmission remains installed.

  Remove

1.   Remove shift mechanism cover (1) •   see operation "Gearshift Cover, Remove and Install and/or Seal (F13/F17/F17+/F18)" 2.   Remove reversing lamp switch (2) •   Disconnect reversing lamp (3) switch wiring harness plug •   Unscrew reversing lamp switch 3.   Remove end shield (4) cover •   See operation "Gasket for End Shield Cover, Replace (F13/F17/F17+/F18)". 4.   Remove end shield (5) •   See operation "Gasket for End Shield, Replace (F13/F17/F17+/F18)". 5.   Remove main shaft •   see operation "End Shield, Dismantle and Assemble (F17+)"

6.   Detach 1st gear •   Press 1st gear off main shaft (4) using KM-307-B (2) and KM-736 (1) •   Remove gear and thrust washer (3) 7.   Remove synchroniser rings 1st gear •   Remove needle bearing, inner synchroniser ring (5), intermediate ring (6) and outer synchroniser ring (7) 8.   Remove synchromesh body retaining ring •   Remove needle bearing •   Remove retaining ring synchro body 1st/2nd gear using KM-396 (8)

9.   Detach 2nd gear •   Press synchro body assembly 1st/2nd gear and gear wheel for 2nd gear (1) off main shaft with KM-307-B and KM-736 •   • Remove shift sleeve 1st/2nd gear (2), outer synchro ring (3). intermediate ring (4) and inner synchro ring (5) from gear wheel of 2nd gear (6) and needle bearing 10.   Detach thrust washer halves (arrows) •   Remove retaining ring (7) •   Detach thrust washer halves 11.   Remove 3rd gear gearwheel (8) 12.   Remove retaining ring synchro body 3rd/4th gear •   Remove 2x slotted needle bearings (9) •   Remove 3rd gear (10) synchroniser ring •   Remove retaining ring synchro body 3rd/4th gear using KM-396 (11) •   Remove spacing ring from synchromesh body

13.   Detach 4th gear •   Press off gear wheel, 4th gear (4), and synchro body with KM-307-B •   Remove synchro body 3rd/4th gear assembly (2), synchro ring 4th gear (3) from 4th gear 14.   Detach needle bearing (5) •   Remove 2x slotted needle bearings from main shaft Note:   Open needle bearing

  Install

Important:   Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid. If a synchromesh body assembly has been completely dismantled then the following method of procedure shall be observed for assembly. 17.   Assemble synchromesh body •   Insert synchro body (1) into shift sleeve (2). •   Insert 3x thrust piece (3) Note:   Position at an angle and then press into the synchro body assembly.

18.   Fit needle bearing (1) •   Place 2x slotted needle bearing on main shaft and clip together Important:   Synchroniser ring lugs must be aligned with synchromesh body grooves. 19.   Attach synchro body assembly 3rd/4th gear •   Position 4th gear synchro ring (3) and synchro body assembly (2) on 4th gear (4). Note:   Groove on slider sleeve (arrow) points to 4th gear. •   Press synchro body assembly (6) and 4th gear (5) on to main shaft

20.   Fit 3rd gear •   Locate spacing ring on synchromesh body •   Fit new retaining ring using KM-396 (3) Note:   Retaining ring must sit in groove correctly. •   Locate synchroniser ring 3rd gear (2) on synchromesh body assembly •   Attach 2x slotted needle bearings (1) to main shaft. •   Locate 3rd gear (5) on main shaft •   Fit both halves of the thrust washer (arrows) and retaining ring (4) using grease Important:   Lugs of the synchro rings must be flush with the grooves of the synchro body and the gear wheel. 21.   Attach synchro body assembly 1st/2nd gear •   Place needle bearing on main shaft •   Locate synchro body 1st/2nd gear (6) with inner synchro ring (9), intermediate ring (8) and outer synchro ring (7) on gear wheel for 2nd gear (10) •   Press synchro body assembly 1st/2nd gear (12) on to main shaft with 2nd gear (11)

22.   Secure synchro body assembly 1st/2nd gear (3) •   Insert new retaining ring (1) using KM-396 (2) Note:   Retaining ring must sit in groove correctly. 23.   Attach 1st gear (5) •   Locate slotted needle bearing (6) on main shaft Important:   Lugs of the synchro rings must be flush with the grooves of the synchro body and the gear wheel. •   Locate 1st gear with inner synchro ring (9), intermediate ring (8) and outer synchro ring (7) on synchro body assembly 1st/2nd gear (10) 24.   Fit thrust washer 1st gear (4) •   Press thrust washer onto main shaft (11) using KM-307-B

27.   Install end shield (1) Note:   Note magnet. •   See operation "Gasket for End Shield, Replace (F13/F17/F17+/F18)". 28.   Fit end shield (2) cover •   See operation "Gasket for End Shield Cover, Replace (F13/F17/F17+/F18)". 29.   Fit gearshift cover (5) •   see operation "Gearshift Cover, Remove and Install and/or Seal (F13/F17/F17+/F18)" 30.   Transmission Fluid Level, Check and Correct •   see operation "Transmission Fluid, Check and Correct (F13/F17/F17+/F18)" 31.   Fit reversing lamp switch (3) •   insert with new seal ring •   Tighten reversing lamp switch – Tightening torque 20 Nm •   Connect wiring harness plug (4)