Vauxhall Workshop Service and Repair Manuals

Remove snap ring for slow and reverse clutch

using Tool KM-J-28585.

Note: Thick version of snap ring (2.36 mm/0.093 in.).

Insert tool KM-J-28542 into reverse clutch housing and lock by turning grip.

Pull out reverse clutch.

Note: A = Bore for fluid guide

Remove thrust washer for axial play.

Note:    Select thrust washer on basis of thrust washer table for axial play.

Important:     Gasket for reverse clutch fluid line must, if slow and reverse clutch were removed, always be replaced.

Knock in gasket (1) using Tool KM-J-28630 and remove.

Remove Tool KM-J-28630.

Remove snap ring with Tool KM-J-28585.

Note: Thin version of snap ring.

Remove axle drive shaft with reaction planetary gear train, sprag cage assembly and clutch plates for slow and reverse clutch from main case.

Axial Play between Differential and Main Case, Measure

Note:    Turn main case so that differential side points upwards.

Install Tools KM-J-26958-A, KM-482 and Dial Indicator KM-J-8001 or Dial Indicator MKM-572.

Depress Tool KM-J-26958-A and set gauge to "0".

Lift governor drive gear with Tool KM-J-28585.

Axial play must lie between 0.12 and 0.82 mm/0.005 and 0.032 in.

Remove Measuring Tool.

If axial play is not correct, select correct thrust washer on basis of the following table.

Thrust washer "A" lies between differential and axial needle bearing "B".

Note: Re-measure thickness of selected thrust washer.

Thrust Washer Table for Axial Play between Differential and Main Case

Identification/Number (Colour)                Thickness

0   (orange)             1.40 to 1.50 mm/0.055 to 0.059 in.

1   (white)               1.50 to 1.60 mm/0.059 to 0.063 in.

2   (blue)                 1.60 to 1.70 mm/0.063 to 0.067 in.

3   (pink)                 1.70 to 1.80 mm/0.067 to 0.071 in.

4   (brown)             1.80 to 1.90 mm/0.071 to 0.075 in.

5   (green)              1.90 to 2.00 mm/0.075 to 0.079 in.

6   (black)               2.00 to 2.10 mm/0.079 to 0.083 in.

7   (purple)             2.10 to 2.20 mm/0.083 to 0.087 in.

8   (purple/white)   2.20 to 2.30 mm/0.087 to 0.091 in.

9   (purple/blue)     2.30 to 2.40 mm/0.091 to 0.094 in.

Remove snap ring with KM-J-28585.

Note: Thick version of snap ring (2.36 mm/0.093 in.).

Remove spacer.

Note:  Observe installation position.

            Lugs "A" must engage in cut-out for parking lock on left and right.

Place Tool KM-J-28545 on axle drive.

Note:  Slide sliding sleeve downwards, thereby locking tool.

Lever out axle drive and remove Tool KM-J-28545.

Remove thrust washer (selective) and needle bearing for differential.

Note:  Observe installation position.

            Black side of needle bearing points to differential.