Vauxhall Workshop Service and Repair Manuals

Axial Play (Input Shaft), Measure

Insert adapter plug of Tool KM-J-26958-A on output shaft.

Bolt Tool KM-J-26958-A onto housing using 2 bolts ("A", M10x25) and in addition bolt on bracket with fastening bolt for transmission fluid pan.

Put axle drive under load by turning control grip inwards.

Correct loading is obtained when grip has been completely turned inwards.

Mount Measuring Tool KM-J-28544, Indicator Bolt KM-482 as well as Dial Indicator KM-J-8001 or Dial Indicator MKM-572.

Press down Measuring Tool KM-J-28544, in doing so set dial gauge to 0.

Measure axial play by lifting measuring tool.

Axial play lies between 0.10 and 0.84 mm. (0.004 and 0.033 in.)

If axial play is not correct, select correct retainer ring on basis of the following table.

The retainer ring is located on the input shaft of the clutch housing for the forward clutch.

A = Retainer ring for axial play

Retainer Ring Table for Axial Play - Input Shaft

  Identification/colour:         Thickness:

     White              1.83 to 1.93 mm/0.072 to 0.076 in.

     Blue                2.03 to 2.13 mm/0.080 to 0.084 in.

     Red                 2.23 to 2.33 mm/0.088 to 0.092 in.

     Yellow            2.43 to 2.53 mm/0.096 to 0.010 in.

     Green             2.63 to 2.73 mm/0.104 to 0.108 in.

In order to ensure that marking on retainer ring is correct, check thickness of rings.

Retainer ring can be removed and installed using Ring Pliers KM-396 after direct clutch housing has been removed.

Important: Do not widen new retainer ring more than necessary.

Remove cover for fluid pump valve body (11 screws).

Gasket must not be reused.

Unbolt kickdown actuation (1) (2 screws) and remove.

Unbolt fluid pump valve body.

Note:    Do not unscrew screw "A" on fluid pump cover.

              Unscrew screw "B" with Torx No. 40. 1 screw for fluid pump valve body is covered (see arrow).

Remove bracket for cold running pipe.

Remove fluid pump valve body with backing plate and gaskets.

Gaskets must not be reused.

Note:        Ensure that ball in valve body is not lost.

Pull out drive shaft for fluid pump.

Note:        Observe difference between drive shafts.

                  A = Drive shaft - new version

                  B = Drive shaft - old version

Remove 5 check balls from cover for main case.

Note:    Make sure that balls are not lost.

Note:    Press out selector slide linkage using screwdriver.

Unbolt cover for main case and remove with gasket. Gasket must not be reused.

Note:    Observe different screw lengths.

              Unscrew screw "A" with Torx No. 40.

Remove accumulator spring for 1-2 accumulator.

Remove needle bearing from driven sprocket wheel.

Remove sprockets and chain together.

Note:    Observe installation position of chain (coloured marking upwards).

Remove gasket and 1-2 accumulator piston. Gasket must not be reused.

Note:    Check accumulator piston for wear and damage, if necessary replace by new parts.

Remove thrust washers of driving and driven sprockets.

Remove selector shaft. To do this, lever out locking pin using pliers.

Note:    Do not damage casing sealing surfaces; if necessary place suitable sheet metal strip underneath.

Knock out spring pin with 4 mm/0.16 in. punch.

Note:    If not already the case, unbolt bracket for parking lock linkage (2 screws) and detach actuator assembly for parking lock from selector shaft.

Pull out selector shaft.

Remove carrier for driven sprocket wheel.

Check carrier for driven sprocket for wear and damage, if necessary replace by new parts.

Note:    Seal rings (3 rings) have slots.

              Do not overstretch when installing.

Remove thrust washer (1) from clutch housing for direct clutch and plug (2) for brake band.

Remove brake band (3).

Remove direct clutch and forward clutch from main case as an assembly.

Remove bronze washer.

Remove input ring gear.

Remove friction washer (1), input planetary carrier (2), friction washer (3) and input sun gear (4) from input drum.

Remove input drum.