Vauxhall Workshop Service and Repair Manuals

Assemblies in Main Case, Install

 

Cement thrust washer (selective) and axial needle bearing to carrier for differential using Installation Grease 19 42 530 (90 093 201 Petrolatum).

Note: Black side of axial needle bearing points towards differential.

 

Insert axle drive in main case using Tool KM-J-28545.

 

Insert spacer.

Note: Lugs must be seated right and left on cut-out for parking pawl.

 

Install snap ring.

 

Measure axial play between differential and main case using KM-J-26958-A, KM-482 and KM-J-8001 (or MKM-572).

Note: Axial play must be between 0.12 and 0.82 mm (0.0047 and 0.0323 in.).

 

Insert shaft for axle drive in main case with reaction planetary gear and sprag cage assembly.

Note: Be sure that reaction planetary gear is not seated on spacer.

 

Insert backing plate, cushion spring, clutch plates (alternately lined and steel plates) and cushion spring.

Note: Beforehand immerse clutch plates in transmission fluid.

 

Install snap ring - thin version (1.07 mm/0.067 in.).

Insert thrust washer (selective) for axial bearing.

Install slow and reverse clutch in main case using Tool KM-J-28542.

Install snap ring - thick version (2.36 mm/0.092 in.).

 

Insert reaction sun gear with mounted retainer ring (selective).

Measure axial play between clutch housing for reverse clutch and sprag race assembly using Tools KM-J-28588, KM-482 and KM-J-8001 (or MKM-572).

Note: Axial play must be between 0.08 and 1.17 mm (0.0032 and 0.0460 in.).

Measure axial play between reaction sun gear and input drum using Tools KM-J-28588, KM-482 and KM-J-8001 (or MKM-572).

Note: Axial play must lie between -0.13 and +0.33 mm (-0.0051 and + 0.0129 in.) from "0".

 

 

Place input drum on reaction gear.   Install input gear.   Note:  Chamfer (see arrow) of input sun gear points outwards.

 

 

Install friction washer and input planetary carrier assembly on input sun gear.   Note:  Fix friction washer on input planetary carrier assembly using Installation Grease 19 42 530 (90 093 201 Petrolatum).   Place friction washer on input planetary carrier assembly.   Insert input ring gear and bronze plate.

 

 

Place assembled direct clutch and forward clutch in main case.   In order to be sure that all assemblies have been installed correctly, depth of insertion should be measured as shown in illustration. Measurement "X" should be approx. 42 mm/1.68 in.

 

 

Insert brake band assembly and install plug for brake band.   Install thrust washer on clutch housing for direct clutch using Installation Grease 18 42 530 (90 093 201 Petrolatum).   Install carrier for driven sprocket.   Note:  In doing so, do not damage seal ring on carrier.             Carrier for driven sprocket is correctly seated if carrier flange (1) is located under fore-part (2) of accumulator housing.

Install selector shaft in main case.   Install thrust washers for driving and driven sprockets on corresponding sprockets using Installation Grease 19 42 530 (90 093 201 Petrolatum).   Insert sprockets together with chain.   Note:  Observe installation position of chain (coloured marking points upwards).   Install new O-ring on shaft for axle drive (on converter side).   Place axial needle bearing on driven sprocket.   Note:  Black side of axial needle bearing points upwards.

 

 

Insert accumulator spring in main case.   Mount new gasket (1).   Screw in 2 guide bolts (2) for installing main case cover.   Mount new gasket (3) on main case.   Install shaft (4) for fluid pump in driving sprocket.

 

 

Insert 1-2 accumulator piston with pin in main case cover.   Note: Observe installation position.   Install thrust washer on main case cover using Installation Grease 19 42 530 (90 093 201 Petrolatum).   Place main case cover over guide bolts on main case and bolt on tight - all bolts with torque 24 Nm/17.70 lbf. ft.   Table for Bolt Lengths   A = M 8 x 45 (4 bolts) B = M 8 x 25 (7 bolts) C = M 8 x 40 (1 bolt) D = M 8 x 55 (4 bolts) E = M 8 x 25 (1 bolt - Torx No. 40) F = M 8 x 25 (1 bolt - Torx No. 40)

 

Install linkage for selector slide.

 

Measure axial play on input shaft. To do so, mount KM-J-26958-A on the output shaft and load.

Install Measuring Tool KM-J-28544, KM-482 as well as Dial Gauge KM-J-8001 (or MKM-572) on the input shaft.

 

Note: Axial play must be between 0.10 and 0.84 mm (0.0039 and 0.0331 in.)

 

Insert 5 check balls in main case cover using Installation Grease 19 42 530 (90 093 201 Petrolatum).

 

Mount gasket, backing plate and additional gasket.

 

Place 1 check ball on backing plate using Installation Grease 19 42 530 (90 093 201 Petrolatum).

 

Install fluid pump valve body on main case cover.

 

Note: Bolt on two guide bolts (Ø 6 mm/0.236 in.) for better installation.

 

 

Bolt on fluid pump valve body tight - M 6 bolts with torque 11 Nm (8.11 lbf. ft.) and M 8 bolts using torque 24 Nm (17.70 lbf. ft.).   Table for Bolt Lengths   A = M 6 x 45       (9 bolts) B = M 6 x 65       (2 bolts) C = M 6 x 25       (4 bolts) D = M 8 x 65      (1 bolt) E = M 8 x 85       (1 bolt - Torx No. 40) F = M 8 x 130     (1 bolt) G = M 6 x 90      (3 bolts)     Note: Also bolt on bracket (1) for cold actuator (2).

 

 

Mount new gasket on main case cover and tightly bolt on cover for fluid pump valve body (11 bolts) - torque 11 Nm (8.11 lbf. ft.).

 

 

Drive in gasket for slow and reverse clutch using Tool KM-J-28630.   Note:  Gasket must be firmly seated, otherwise leakage between reverse clutch housing and main case occurs.   Install slow and reverse clutch fluid line.   Note:  Mount supporting ring and O-ring on fluid line and attach fluid line using bracket - torque 24 Nm/17.70 lbf. ft.

 

 

Install shaft for axle drive.   Install new snap ring using Tool KM-481.   In order to be sure that snap ring is correctly seated, fit on snap ring using Tool KM-J-28583.

 

Install cover in main case.

 

Attach clamp for governor fluid line using bracket for cover - torque 24 Nm/17.70 lbf. ft.

 

Attach parking pawl linkage and fasten using bracket - torque 24 Nm/17.70 lbf. ft.

 

Check brake band assembly adjustment using Checking Tool KM-J-28535 and commercially available torque wrench.

 

Note: Press down Checking Tool with 11.2 Nm (8.26 lbf. ft.) and determine corresponding actuator pin.

 

Assemble servo piston for brake band and insert in main case.

 

Insert accumulator non-return valve and spring in main case.

 

Mount new gasket, mount cover for brake band servo piston, and bolt on tight - torque 11 Nm/8.11 lbf. ft.

 

Note: Bolt on together with bracket for reverse clutch fluid line.

 

Install fluid filter with gasket - see operation "Fluid Filter, Replace" in this group.

 

Mount new gasket and bolt on transmission fluid pan (16 bolts) - torque 11 Nm/8.11 lbf. ft.

 

Replace O-ring on governor shaft.

 

Insert governor with speedo driving gear and axial needle bearing.

 

Install new O-ring in governor cover and bolt on governor cover - torque 11 Nm/8.11 lbf. ft.

 

Install speedo driven gear - see operation "Speedo Gear (Driven), Replace" in this group.

 

Remove transmission from Base KM-113-2 and install converter in converter housing.

 

Remove Holding Fixture KM-480 from transmission.