Vauxhall Workshop Service and Repair Manuals

End plate, dismantle and reassemble (F13+/F13+ MTA)

Note:   Transmission remains installed.

Overview end plate

  Remove

2.   Install end plate on KM-552 (2) 3.   Install end plate with KM-552 on KM-113-2 (1)

4.   Remove bearing block (1) with rocker arm (2) from end plate Note:   Microencapsulated screws. If the screws do not move easily, heat the end plate using industrial heat gun to approx. 80°C. •   Unscrew 2x screw

5.   Remove gear wheel 5th gear (driven) •   Remove lock ring from synchroniser body (1) •   Remove gear wheel 5th gear and synchroniser body 5th gear with KM-161-B (2) from main shaft •   Remove 2x needle bearings for gear wheel 5th gear

6.   Remove pressure disc (1) and 2x split shell (2)

7.   Remove lock ring (1) from gear wheel 5th gear (driving (2)

8.   Remove gear wheel 5th gear (driving) with KM-553-A (1) from drive shaft Note:   Note correct seating of KM-553-A on gear wheel 5th gear (driving). •   Place thrust piece (2) for KM-553-A on drive shaft

9.   Remove bearing block (2) with pawl (1) from end plate •   Unscrew 2x screw (arrow) Note:   Microencapsulated screws. If the screws do not move easily, heat the end plate using industrial heat gun to approx. 80°C.

10.   Remove 4x locking plug (arrow) from end plate •   Remove locking plug with KM-727 (2) and KM-328-B (1)

11.   Remove bridge (1) for locking bolt from end plate •   Engage 3rd gear •   Engage 5th gear (arrow pointing right) •   Unscrew 2x screw (2) Note:   Microencapsulated screws. If the screws do not move easily, heat the end plate using industrial heat gun to approx. 80°C. •   Engage 2nd gear (arrow pointing left) Note:   When 2nd gear is engaged, the bridge for the locking bolt springs out of the end plate.

Important:   Relieve load from shift rod guide - to do this, prop top shift rods with wooden wedge (1). 12.   Remove shift fork 3rd/4th gear (3) and shift fork reverse gear (6) Note:   Note installation position. •   Knock roll pins (arrow) out of shift fork 3rd/4th gear and shift fork reverse gear with KM-308 •   Remove shift rod (2), shift rod reverse gear and shift fork Note:   Note installation position. 13.   Remove shift driver 5th gear (4) from end plate 14.   Remove locking bolt (5) for locking from end plate

15.   Remove reverse gear wheel (6) from reverse gear wheel axle 16.   Remove shift fork (3) with shift rod 1st/2nd gear (2) from end plate Note:   Note installation position. •   Remove roll pin (4) with KM-308 Important:   When knocking out the main and drive shaft with mallet, ensure that the toothed gears of the shafts do not touch or tilt. Knock main and drive shaft out using mallet alternatingly. 17.   Press main shaft (1) out of end plate or knock out with mallet 18.   Press drive shaft (5) out of end plate or knock out with mallet

19.   Remove reverse gear wheel axle from end plate •   Tighten reverse gear wheel axle in vice with braces •   Carefully knock end plate out with mallet Note:   Ensure that locking ball (arrow) remains free.

20.   Remove drive shaft bearing (1) from end plate •   Remove lock ring (4) •   Press bearing out with KM-500-5 21.   Remove main shaft bearing (2) from end plate •   Remove lock ring (3) •   Press bearing out with KM-500-5

  Install

25.   Install drive shaft bearing (1) in end plate •   Press bearing in with KM-519 •   Install lock ring (4) 26.   Install main shaft bearing (2) in end plate •   Press bearing in with KM-373-1 •   Install lock ring (3)

Important:   Note installation position. 27.   Press reverse gear wheel axle into end plate •   Insert locking ball (arrow) •   Press in reverse gear wheel axle up to stop Note:   Locking ball must sit in groove of end plate

28.   Insert reverse gear wheel (5) in end plate Note:   Reverse gear wheel shift fork groove (arrow) points upward. Important:   Wet bearing and return hole with transmission oil. 29.   Press main shaft (2) and drive shaft (1) into end plate with KM-6337 and KM-6338 Note:   Note installation position. Place main and drive shaft on KM-6337 . 30.   Insert shift fork (4) with shift rod 1st/2nd gear (3) in end plate Note:   Note installation position.

31.   Install locking bolt (1) reverse gear and 3rd/4th gear 32.   Relieve load from shift rod guides in end plate •   Support shift rods with wooden wedge during pin insertion 33.   Install shift fork (5) and shift rod reverse gear (6) •   Drive roll pin in with KM-308 (4) Note:   Allow new roll pin to project approx. 2 mm (dimension I). 34.   Install roll pin for shift fork (3) and shift rod (2) 1st/2nd gear •   Drive roll pin in with KM-308 (4) Note:   Allow new roll pin to project approx. 2 mm (dimension I).

35.   Install shift driver 5th gear (4) 36.   Install shift fork (2) and shift rod 3rd/4th gear (1) Note:   Note installation position. •   Drive roll pin in with KM-308 (3) Note:   Allow new roll pin to project approx. 2 mm (dimension I). 37.   Install 4x locking plug (5 - 7) •   Drive locking plug in with mallet or soft metal driver up to stop 38.   Move shift fork to idle position

39.   Install bridge (2) for locking bolt on end plate •   Engage 2nd gear •   Engage 3rd gear •   Engage 5th gear •   Insert bridge for locking bolt •   Screw in 2x new screw (1) Note:   Wet screws with locking compound. 40.   Change shift fork 1st/2nd gear to neutral 41.   Tighten 2x screw bridge 7 Nm 42.   Move shift fork to idle position 43.   Install bearing block (4) on end plate with pawl (3) •   Tighten 2x screw (arrow) 9 Nm Note:   Wet screws with locking compound.

44.   Remove end plate with KM-552 from KM-113-2 Important:   Long gear wheel hub points to end plate. 45.   Press gear wheel 5th gear (driving) (1) onto drive shaft with KM-473 •   Insert end plate with main shaft and drive shaft in KM-554 (2) •   Install new locking ring (3)

47.   Insert pressure disc (1) and 2x split shell (2)

48.   Install gear wheel 5th gear (driven) (2) on main shaft •   Install 2x needle bearing (1) on main shaft Note:   Ensure correct seating of split needle bearing. – Wet 2x needle bearing with transmission oil

49.   Press gear wheel 5th gear (driven) (3) and synchroniser body (1) onto main shaft with KM-473 Note:   Note installation position. Tips of teeth of synchroniser sleeve of synchroniser body point to end plate. •   Wet seating surface of main shaft and synchroniser body with transmission oil •   Install new lock ring (2)

50.   Insert 2x sliding block (arrows) in shift fork 5th gear 51.   Install bearing block with rocker arm (1) on end plate •   Tighten 2x new screw 22 Nm Note:   Insert screws with locking compound.

52.   Install thrust washer (arrow) on reverse gear wheel axle Note:   Bond thrust washer with grease. 53.   Conduct visual inspection for correct position and correct seating 1. Shift rod 3rd/4th gear 2. Shift fork 3rd/4th gear 3. Shift driver 5th gear 4. Shift rod 1st/2nd gear 5. Shift fork 1st/2nd gear 6. Locking bolt for gear retention 7. Shift fork reverse gear 8. Shift rod reverse gear 54.   Check gearshift function Shift through all gears

55.   Remove end plate from KM-113-2 (1) and KM-552 (2)