Astra
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End Shield, Assemble and Install (4-Speed Manual Transmission)
Guide main shaft, turbine shaft, shift fork and shift rod for 1st and 2nd gear and reverse idler gear into end shield.
Secure main shaft and turbine shaft with snap rings.
Secure shift forks and 3rd and 4th gear shift rods as well as reverse gear with retaining pins using KM-308.
Insert 3 detent pins with pressure springs and drive in plugs.
Select 2nd gear with shift sleeve.
If previously removed, drive or press roller bushing supporting main shaft ("F 10" and "F 13" only, in "F 16" and "F 20" outer bushing for bearing) and needle bushing supporting turbine shaft flush into main case using special service tool. Carefully insert completely assembled end shield into main case and bolt in place - 15 Nm/11.06 lbf. ft.
End Shield, Assemble and Install (5-Speed Manual Transmission)
Insert locking pins for gear detent, main shaft, turbine shaft, shift fork and shift fork of 1st and 2nd gear and reverse idler gear in end shield. Secure main shaft and turbine shaft with snap ring. Insert shift rod and shift fork of reverse gear, shift driver of 5th gear and shift fork and shift rods of 3rd and 4th gear in end shield. Tighten bracket for locking pins to end shield - 7 Nm/5.16 lbf. ft. Tighten bearing support and pawl to end shield - 30 Nm/22.13 lbf. ft. Drive 4 plugs for detent pins oil-tight into end shield.
Mount end shield assembly on KM-554. Press 5th gear (large) onto gear cluster using KM-466-3. Secure 5th gear (large) with new snap ring. Slide 5th gear (small) and synchronizer ring onto main shaft. Press synchromesh body for 5th gear onto main shaft using KM-334. Bolt bearing support with rocker arm to end shield - 22 Nm/16.23 lbf. ft. Carefully insert completely assembled end shield in main case and tighten - 15 Nm/11.06 lbf. ft.
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