vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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End Shield, Assemble - 5-Speed Manual Transmission > < End Shield with Main Shaft and Turbine Shaft, Remove and Disassemble

Astra

End Shield, Assemble - 4-Speed Manual Transmission

 

Press reverse idler gear shaft, with locking ball in place, into end shield as far as stop.

       On F 16, place KM-522 underneath when pressing in.

 

Insert both locking studs (B 2596/1) for gear detent in holes in end shield.

Insert pins in shift fork and shift rod of 1st and 2nd gear (B 2596/7) using KM-308/2.

       Allow new retaining pin to protrude approx. 2 mm /0.08 in.

 

 

 

Object Number: 2374325 Size: DEFAULT

 

 

Insert main shaft, turbine shaft, shift fork, shift rod for 1st and 2nd gear and reverse idler gear in end shield.

       End shield bolted to Installer KM-552.

 

       Shift fork groove of reverse idler gear points upwards (illus. B 9149).

 

       Coat bore of reverse idler gear with Extreme Pressure Lubricant 19 70 300 (6 636 630).

       Set 1st and 2nd gear shift sleeve in neutral position.

 

       Mount thrust washer on reverse idler gear shaft.

 

Secure main shaft and turbine shaft with snap rings.

       Snap rings must seat perfectly in their grooves.

       Use KM-443-A for this.

 

       Use new snap rings.

 

Object Number: 2374943 Size: DEFAULT

Install shift fork (B 2569/6) and shift rod (B 2596/5) for 3rd and 4th gear, shift fork (B 2596/3) and shift rod (B 2596/4) for reverse gear and secure with pins using KM-308.

       Use new retaining pins.

 

       Important:

       When installing retaining pins, support all shift rods at top with piece of wood, so that rod guide in end shield is not overloaded.

 

Insert 3 detent pins (B 2596/2) with pressure springs and knock in closure plugs.

       Use new closure plugs (bores must be oil-tight, use oversize plugs if necessary).

 

Select 2nd gear with shift sleeve.

 

 

 

B 2596/1: Locking pins for gear detent

B 2596/2: Detent pins with pressure spring

B 2596/3: Shift fork, reverse gear

B 2596/4: Shift rod, reverse gear

B 2596/5: Shift rod, 3rd and 4th gear

B 2596/6: Shift fork, 3rd and 4th gear

B 2596/7: Shift fork and shift rod, 1st and 2nd gear

 

Object Number: 2374326 Size: DEFAULT

 

 

Carefully insert completely assembled end shield into main case.

       Stick seal to main case with antifriction bearing grease.

 

Bolt end shield to main case - 15 Nm/11.06 lbf. ft.

 

Assemble and install speedometer helical gear (driven).

       Bolt on retaining plate - 4 Nm/2.95 lbf. ft.

 

       Coat splines of helical gear with Antifriction Bearing Grease 19 41 574 (90 001 812).

 

Bolt in reversing lamp switch - 20 Nm/14.75 lbf. ft.

 

 

Object Number: 2374295 Size: DEFAULT

 

 

End Shield, Assemble - 5-Speed Manual Transmission > < End Shield with Main Shaft and Turbine Shaft, Remove and Disassemble