Astra
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Transmission Mainshaft, Disassemble
F 10 Manual Transmission Press out ball bearing, spacing washer and 1st gear using suitable drift (remove snap ring).
Press out 1st and 2nd gear synchromesh body and 2nd gear using KM-307-B (remove snap ring). Press main shaft gear from main shaft using KM-307-B and a suitable drift (remove snap ring).
Pull off spacing washer and 4th gear using KM-479-A.
Press off 3rd and 4th gear synchromesh body and 3rd gear (remove snap ring).
F 13 Manual Transmission Press off ball bearing, axial needle bearing and 1st gear using suitable drift (remove snap ring). Press off 1st and 2nd gear synchromesh body and 2nd gear using KM-307-B (remove snap ring).
Beforehand, remove synchronizer rings of 1st gear. Press main shaft gear from main shaft using KM-307-B and a suitable drift (remove snap ring).
Press off spacing washers and 4th gear using KM-479-A. Press off 3rd and 4th gear synchromesh body and 3rd gear (remove snap ring).
F 16 Manual Transmission Press off ball bearing, spacing washer, axial needle bearing and 1st gear using suitable drift (remove snap ring). Remove needle bearing for 1st gear. Press off synchromesh body for 1st and 2nd gears and press off 2nd gear as well (remove snap ring). Remove needle bearing for 2nd gear. Remove both halves of thrust washer, 3rd gear and needle bearing (slotted). Press off synchromesh body for 3rd and 4th gears and press off 4th gear as well (remove snap ring and washer). Remove needle bearing (slotted) for 4th gear, both halves of thrust washer and roller bearing.
F 20 Manual Transmission Press off ball bearing, spacing washer, axial needle bearing and 1st gear using suitable drift. Remove needle bearing for 1st gear. Press off synchromesh body for 1st and 2nd gears and press off 2nd gear as well (remove snap ring). Remove needle bearing for 2nd gear. Remove both halves of thrust washer, 3rd gear and needle bearing (slotted). Press off synchromesh body for 3rd and 4th gears and press off 4th gear as well (remove snap ring and washer). Remove needle bearing (slotted) for 4th gear. Remove gear. Prise up and remove roller bearing (slotted).
If necessary, on "F 10", "F 13", "F 16" and "F 20" manual transmission, remove needle bushing for supporting turbine shaft from main case using special tool.
Install
Clean all removed parts and check for wear, scoring, damage and hair line cracks, replacing if necessary. Replace rings, synchronizer springs and sliding blocks.
Thoroughly coat bearing and contact surfaces of all rotating parts on seating surfaces slid or pressed into place with Extreme Pressure Transmission Fluid 19 40 750/90 001 777.
On "F 10", all synchromesh bodies, sliding blocks, synchronizer rings and spacing washers are interchangeable. On "F 13", three-cone synchronization.
Assemble transmission main shaft.
F 10 Manual Transmission Mount 3rd gear on main shaft and synchronizer ring on 3rd gear.
Press on 3rd and 4th gear synchromesh body using KM-277 and secure with snap ring. Important: Heat synchromesh body to 100 °C/212 °F.
Slide on synchronizer ring and 4th gear.
Press on spacing washer and main shaft gear using KM-311 and secure with retaining pin. Important: Heat spacing washer and main shaft gear 100 °C/212 °F.
Mount 2nd gear on main shaft and synchronizer ring on 2nd gear.
Press on 1st and 2nd gear synchromesh body using KM-277 and secure with snap ring. Important: Heat synchromesh body to 100 °C/212 °F. Slide on synchronizer ring and 1st gear; press on spacing washer and ball bearing using KM-311 and secure with snap ring. Important: Heat spacing washer to 100 °C/212 °F.
F 13 Manual transmission Mount 3rd gear on main shaft and synchronizer ring on 3rd gear. Press on synchromesh body assembly for 3rd and 4th gear using KM-277 and secure with snap ring. Important: Heat synchronizer ring assembly to 100 °C/212 °F. Slide on synchronizer ring and 4th gear. Press on spacing washers and main shaft gear using KM-311 and secure with snap ring.
Important: Heat spacing washer and turbine shaft to 100 °C/212 °F. Place 2nd gear on main shaft and synchronizer ring on 2nd gear. ress on synchromesh body assembly for 1st and 2nd gear using KM-277 and secure with snap ring. Important: Heat synchromesh body assembly to 100 °C/212 °F. Slide on synchronizer rings for 1st gear and axial needle bearing and press on spacing washer and ball bearing using KM-311. Secure with snap ring. Important: Heat spacing washer to 100 °C/212 °F.
F 16 Manual Transmission: Slide on roller bearing, both halves of thrust washer, needle bearing (slotted) and 4th gear. Mount synchronizer ring on cone of 4th gear. Press on synchromesh body for 3rd and 4th gear using KM-514 and secure with snap ring (washer). Important: Heat synchromesh body to 100 °C/212 °F. Slide on needle bearing (slotted) and 3rd gear. Mount synchronizer ring on cone of 3rd gear. Slide on both halves of thrust washer, needle bearing and 2nd gear. Mount synchronizer ring on cone of 2nd gear. Press on synchromesh body for 1st and 2nd gear using KM-514 and secure with snap ring. Important: Heat synchromesh body to 100 °C/212 °F. Mount needle bearing and 1st gear. Position axial needle bearing in front of 1st gear. Press on spacing washer and then ball bearing using KM-311 and secure with snap ring. Important: Heat spacing washer to 100 °C/212 °F.
F 20 Manual Transmission: Mount roller bearing (slotted) on main shaft and lock. Cage must snap audibly on locking.
Push on needle bearing (slotted) 4th gear. Place synchronizer ring on cone of 4th gear. Press main shaft into synchromesh body 3rd and 4th gears (with synchronizer ring and 4th gear) using KM-514 and KM-307-B and secure with retainer ring (washer). Important: Heat synchromesh body to 100 °C/212 °F. Slide on needle bearing (slotted) and 3rd gear. Mount synchronizer ring on cone of 3rd gear. Slide on both halves of thrust washer, needle bearing and 2nd gear. Mount synchronizer ring on cone of 2nd gear. Press on synchromesh body for 1st and 2nd gear using KM-514 and secure with snap ring. Important: Heat synchromesh body to 100 °C/212 °F. Mount needle bearing and 1st gear. Position axial needle bearing in front of 1st gear. Press on spacing washer and then ball bearing using KM-311 and secure with snap ring. Important: Heat spacing washer to 100 °C/212 °F.
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