Astra
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Both Drive Pinions (Driving + Driven), Replace F 10 , F 13 F 16 and F 20 - Manual Transmission
These operations are to be carried out with the main case installed.
See "Transmission and Differential, Overhaul" and "Synchronizer Rings, Replace" for additional information.
Drive Pinion (Driven), Remove, 4 and 5-Speed Manual Transmission
Raise vehicle. Remove both front wheels.
Unscrew differential cover from main case (fluid escapes).
Press ball joints out of both steering knuckles using KM-507-C.
Drive both axle shafts out of main case using KM-460-2 (L.H. side, changed tool) and KM-460-1 (R.H. side), for F 16 and F 20 (only 18 E and all 2.0 litre engines) using KM-503-A (L.H. side) and KM-460-2 (R.H. side).
Important: Chamfered side of tool must always face transmission.
Use 1500 gram/3 1/2 lb hammer.
Suspend axle shafts immediately; do not allow to sag.
Mark bearing ring position to ring and main case with their relative positions. Check tapered roller bearings for axial play. Unscrew bearing ring from main case using KM-447 (F 10 and F 13) or KM-520 (F 16 and F 20) and remove differential.
Clamp differential housing in vice using KM-458-A (F 10 and F 13) or KM-524-A (part 1) (F 16 and F 20).
Unbolt ring gear from differential housing and knock off with brass drift.
Drive Pinion (Driving), Remove - 4-Speed Manual Transmission
Loosen screw for shift linkage clamp and separate linkage from transmission.
On vehicles with catalytic converter: remove pin of universal joint at shift linkage (remove retaining clips from pin). Unbolt shift mechanism cover from main case and remove. Shift transmission into 2nd gear.
Remove screw cover from end shield.
Unscrew fillister head screw from turbine shaft (remove snap ring).
Pull transmission turbine shaft as far as stop using KM-556-1-A (previously KM-449-1 in conjunction with Kukko Counterstay 22-1). Do not actuate clutch beyond this point.
Unscrew reversing lamp switch.
Unbolt end shield from main case.
Pull end shield with mainshaft and turbine shaft from main case and bolt to Installer KM-552.
Knock 3 plugs for shift detent out of end shield using KM-457-A in conjunction with KM-328-B.
Drive locking pins out of 3rd and 4th gear shift fork and reverse gear shift fork using punch.
Remove shift rods and shift forks for 3rd and 4th gear and reverse gear from end shield. Remove both snap rings for fastening mainshaft and turbine shaft from end shield.
Pull mainshaft and turbine shaft, reverse idler gear and shift fork with shift rod for 1st and 2nd gear from end shield.
On F 10 and F 13 press mainshaft gear from mainshaft using KM-307-B and suitable drift (remove snap ring).
On F 16 disassemble mainshaft completely. The mainshaft with mainshaft gear is a single component.
If necessary, remove needle sleeve and roller bushing from main case using special tool and press in new parts.
Drive Pinion (Driving), Remove - 5-Speed Manual Transmission
Loosen bolt for shift linkage clamp and separate linkage from transmission.
On vehicles with catalytic converter: remove pins from universal joint at shift linkage (remove retaining clip from pin).
Remove shifting cover from main case.
Put transmission into 2nd gear.
Unscrew screw cover from end shield (on F 20 and all 5-speed manual transmissions as of MY 88 ½: unbolt transmission cover). Pull out transmission turbine shaft as far as stop using 556-1-A (previously KM-449-1 in conjunction with Kukko Counterstay 22-1). Do not actuate clutch beyond this point.
Unscrew reversing lamp.
Unscrew end shield from main case.
Remove end shield with mainshaft and turbine shaft from main case and screw to Installer KM-552.
Unscrew bearing support with rocker arm from end shield.
Pull synchromesh body for 5th gear from mainshaft using KM-161-A together with Hooks KM-161-2. To do this, remove snap ring from synchromesh body.
Remove the following from mainshaft: 5th gear (small), needle bearing for 5th gear, snap ring for thrust washers and both halves of thrust washers.
The needle bearing (on F 16 and F 20: two parts) is slotted and can be bent up slightly.
Remove 5th gear (large) from gear cluster using KM-553-A. Place pressure piece underneath. Beforehand, remove snap ring from gear.
Unbolt bearing support with pawl from end shield.
Knock 4 plugs for shift detent out of end shield using KM-457-A in conjunction with KM-328-B. Unbolt bridge for locking pins from end shield and remove. To do this, shift into 2nd gear and (with shift driver) 5th gear. When subsequently shifted into 3rd gear the bridge will slide out.
Drive locking pins out of shift fork for 3rd and 4th gear and reverse gear shift fork using punch. Remove shift rods and shift forks for 3rd and 4th gear and reverse gear from end shield
Pull shift driver for 5th gear out of end shield.
Remove both snap rings for fastening mainshaft and turbine shaft using KM-443-B.
Pull mainshaft and turbine shaft, reverse idler gear and shift fork and shift rod for 1st and 2nd gear out of end shield.
On F 10 and F 13: Press off mainshaft gear from mainshaft using KM-307-B and suitable drift (remove snap ring).
On F 16 and F 20: Completely disassemble mainshaft. Mainshaft and drive pinion (driving) are one assembly. If necessary, pull needle sleeve and roller bushing out of main case using special tool.
Drive Pinion (Driving), Install - 4-Speed Manual Transmission
On F 10 and F 13, press new drive pinion onto main shaft using KM-311-2 and secure with snap ring.
On F 16, completely assemble new mainshaft.
Insert mainshaft, turbine shaft, shift fork and 1st and 2nd gear shift rod as well as reverse idler gear into end shield.
Secure mainshaft and turbine shaft with snap ring.
Insert locking pins in shift forks and shift rods for 3rd and 4th gear and for reverse gear using KM-308.
Insert 3 detent pins with pressure springs and drive in plug closures.
Select 2nd gear with shift sleeve.
Carefully insert completely assembled end shield into main case and bolt in place - 15 Nm/11.06 lbf. ft.
Screw in reversing lamp switch - 20 Nm/14.75 lbf. ft.
Screw fillister head screw into transmission turbine shaft and press turbine shaft into gear cluster as far as stop using KM-564. Secure turbine shaft with snap ring. Install screw cover oil tight into end shield with Sealing Compound 15 03 166 (90 094 714) or PVC tape - 50 Nm/36.88 lbf. ft.
Bolt shift mechanism cover to main case - 22 Nm/16.23 lbf. ft.
Adjust transmission shift linkage (see operation in this group).
Drive Pinion (Driving), Install - 5-Speed Manual Transmission
On F 10 and F 13, press new drive pinion onto mainshaft using KM-311-2 and secure with snap ring.
On F 16 and F 20, completely assemble new mainshaft.
Insert mainshaft, turbine shaft, shift fork and 1st and 2nd gear shift rod as well as reverse idler gear into end shield. Secure mainshaft and turbine shaft with snap ring. Insert shift rod and shift fork for reverse gear, shift driver of 5th gear and shift rods and shift forks for 3rd and 4th gear into end shield. Bolt bridge for locking pins to end shield - 7 Nm/5.16 lbf. ft.
Bolt bearing support and pawl to end shield - 30 Nm/22.13 lbf. ft.
Drive 4 plugs for end shield oil tight into bearing.
Place end shield assembly onto KM-554.
Press 5th gear (large) onto gear cluster using KM-466-3.
Secure 5th gear with new snap ring.
Slide 5th gear (small) and synchronizer ring onto mainshaft.
Press synchromesh body for 5th gear onto mainshaft using KM-334.
Bolt bearing support and rocker arm to end shield - 22 Nm/16.23 lbf. ft.
Put into 2nd gear using shifting sleeve.
Carefully insert completely assembled end shield into main case and screw tight - 15 Nm/11.06 lbf. ft.
Screw in reversing lamp switch - 20 Nm/14.75 lbf. ft.
Insert fillister head screw into transmission turbine shaft. Push turbine shaft into gear cluster until stop using KM-564.
Secure shaft with snap ring.
Screw in screw cover into bearing cover using Sealing Compound 15 03 166 (90 094 714) or PVC tape - 50 Nm/36.88 lbf. ft. (except F 20).
Bolt transmission cover to end shield (only F 20 and all 5-speed manual transmissions as of MY 88 ½). Prescribed torque: M 7 x 1.0 = 15 Nm/11.06 lbf. ft. M 8 x 1.25 = 20 Nm/14.75 lbf. ft.
Tighten shift cover to main case - 22 Nm/16.23 lbf. ft.
Adjust transmission shift linkage (see operation in this group).
Drive Pinion (Driver), Install - 4- and 5-Speed Manual Transmission
Tighten new drive pinion to differential housing - important mounting part, observe prescribed torque. Important: Heat drive pinion to 80 °C/176 °F.
Insert differential in main case.
On F 10 and F 13, screw bearing ring into case using KM-447. Observe section f) of adjustment instructions for tapered roller bearings in the differential.
On F 16 and F 20, screw bearing ring into case using KM-520. Tighten bearing flange. Observe section f) of adjustment instructions for tapered roller bearings in the differential.
Screw cover for differential to main case - sheet metal cover: 30 Nm/22.1 lbf. ft., light alloy cover: 18 Nm/13.3 lbf. ft.
First press both axle shafts into main case. Then push in until snap ring snaps into place using screwdriver. Beforehand, insert new snap ring in groove in joint stub shaft. Important: Do not overload snap ring.
When snap ring snaps into place, check proper seating of axle shaft by pulling by hand at outer diameter of joint.
Important: Proper seating of axle shaft cannot be checked by pulling shaft
Fasten ball joint to steering knuckle with castellated nut and secure with retaining clip - important mounting part, tighten to 70 Nm/51.63 lbf. ft.
Tighten wheel bolts, alternating crosswise 90 Nm/66.38 lbf. ft.
Fill transmission fluid.
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