Astra
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End Shield, Mainshaft and Drive Shaft, Remove and Disassemble - 5-Speed Manual Transmission
Unbolt transmission cover from end shield (not in 5-speed manual transmissions as of MY 88 ½). Unbolt end shield with main shaft and turbine shaft from main case, pull out and bolt to Installer KM-552. Unbolt bearing support with rocker arm from end shield and remove. Pull off 5th gear synchromesh body from main shaft using KM-161-A and Hooks KM-161-2. To do this, engage two gears simultaneously (e.g. 3rd gear and reverse gear). Beforehand remove snap ring in front of synchromesh body.
Remove the following from main shaft: 5th gear (small), needle bearing for 5th gear, snap ring for thrust washers and both halves of thrust washers. Needle bearing is slotted and can be bent up slightly.
Pull off 5th gear (large) from gear cluster. Place pressure piece underneath. Beforehand remove snap ring from gear.
Unbolt bearing support with pawl from gear. Knock 4 plugs for shift detent out of end shield. Unbolt bridge for locking pins from end shield and remove. To do this, engage 2nd gear and 5th gear (with shift driver). When subsequently shifted into 3rd gear, bridge will slide out.
Drive retaining pins out of shift fork for 3rd and 4th gear and out of shift fork for reverse gear 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 main shaft and turbine shaft from end shield using KM-443-B.
Pull main shaft and turbine shaft together with reverse idler gear, shift fork and shift rod for 1st and 2nd gear from end shield.
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