Vauxhall Workshop Service and Repair Manuals

Differential, Remove and Disassemble - 4- and 5-Speed Manual Transmission

F 10 - and  F 13 Manual Transmission

Unbolt differential cover from main case.

Pull both seals out of bearing ring and main case using KM-557 or Kukko Puller 21/6 in conjunction with Kukko Counterstay 22-2 (only when replacing seal rings, if differential remains installed).

Mark bearing ring position on ring and main case.

Check play of tapered roller bearings.

       Move differential housing in axial direction by hand.

       If axial play is present, this is to be taken into

       account during later assembly.

Unscrew bearing ring from main case using KM-447.

       Beforehand, unscrew snap ring.

       Hold differential firmly and remove through cover opening.

With differential removed, two seal rings should be driven out of bearing ring and main case using KM-454-2 and -4.

Drive tapered roller bearing outer race out of bearing ring using KM-304 and KM-451. Place Seal Remover KM-303 underneath.

Drive tapered roller bearing outer race out of main case using KM-304 and KM-451.

With main case installed and for vehicles with a dual pipe exhaust system, KM-305 should be used instead of KM-304.

Pull both tapered roller bearing inner races out of differential housing using KM-161-A in conjunction with Hook KM-161-3 and Pressure Piece KM-161-4.

Unbolt drive pinion from differential housing.

       Knock off drive pinion using brass drift.

       Always replace drive pinions as a pair.

Tap speedometer drive gear from differential housing and destroy.

Remove left and right snap rings from differential pinion shaft.

Drive pinion shaft out of differential housing using drift.

Unscrew differential pinion and side gear from differential housing.

       Remove washers.

F 16 and F 20 Manual Transmission

Unbolt differential cover from main case.

Mark bearing ring position on ring and main case.

Check play of tapered roller bearings.

       Move differential housing by hand in axial direction.

       If axial play is present, this must be taken into account during later reassembly.

Unscrew bearing ring from main case using KM-520.

       Beforehand, remove retaining plate.

Unbolt bearing flange from main case and remove.

       Hold differential firmly and remove through cover opening.

       Replace O-rings in bearing flange and bearing ring.

Press both seal rings out of bearing ring and bearing flange using KM-466-3.

Place KM-466-2 underneath.

Press tapered roller bearing outer race out of bearing ring and bearing flange using KM-304 and KM-451.

Place Spacer Ring KM-502-A underneath.

Pull both tapered roller bearing inner races from differential housing.

       In order to obtain correct seating of puller hooks under tapered roller bearings, speedometer helical driving gear must be removed from differential housing and discarded (illus. B 2571).

Pull roller bearing inner races from differential housing using KM-161-A in conjunction with Hook KM-161-3 and Pressure Piece KM-161-4.

       Illustration shows F 16/5 differential housing.

Unbolt drive pinion (driven) from differential housing.

       Knock off drive pinion using brass drift.

       Always replace drive pinion (driving and driven) as a pair.

       It is not necessary to remove speedometer gear and tapered roller bearings in order to unbolt drive pinion.

F 16/5 Manual Transmission

Unscrew special fillister head screw for retaining bevel gear shaft from differential housing.

       Remove bevel gear shaft from differential housing.

Remove differential pinion and differential side gear from differential housing.

       Remove washers and flat thrust washers from bevel gears.

F 20/5 Manual Transmission

Drive pin securing bevel gear shaft out of differential housing and axle.

       Remove bevel gear shaft and differential and axle shaft bevel gears from differential housing.

       Remove plate washers from differential bevel gears or from differential housing and remove friction washers and diaphragm springs from axle shaft bevel gears.

Clean, Check and Lubricate

Clean all parts removed and check for wear, scoring, damage and hairline cracks: replace if necessary. The main case in particular should be cleaned thoroughly by intensive rinsing.

Apply a generous amount of Extreme Pressure Transmission Lubricant 19 40 750 (90 001 777) to bearing or contact surfaces of rotating parts and to seating surfaces of all parts mounted or pressed into place.