Vauxhall Workshop Service and Repair Manuals

c) Gasket for End Shield, Replace

(except F 20 and all 5-speed manual transmissions as of MY 88 ½)

Raise vehicle. Remove screw cover from end shield.

Unscrew fillister head screw from turbine shaft.

       Beforehand, remove snap ring.

       Mark installation position of transmission turbine shaft in gear cluster with paint.

Withdraw transmission turbine shaft as far as stop using M-556-1-A (previously KM-449-1 in conjunction with Kukko Counterstay 22-1).

       Clutch splines are disengaged. For this reason, do not actuate clutch after this point.

Unscrew reversing lamp switch.

Unbolt end shield from main case.

Withdraw end shield with main shaft and turbine shaft from main case.

       Important: Fluid will escape.

Replace end shield gasket.

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

Stick new gasket to main case with antifriction bearing grease.

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

       By hand carefully insert or slip transmission drive shaft into splines of clutch disc and gear cluster (splines of both shafts must be seated in corresponding tooth gaps of clutch disc and gear cluster).

Illus. C 0037 shows centering after installation of clutch disc.

       Observe paint marks made on turbine shaft and gear cluster during removal.

Screw fillister head screw into transmission turbine shaft and press shaft into gear cluster as far as stop using KM-564.

On 4-speed manual transmission, use 3 spacer sleeves (A - illus. B 8231).

On 5-speed manual transmission (illus. P 0554)

Secure turbine shaft with snap ring.

       Use new snap ring.

Install screw cover oil-tight into bearing cover with Sealing Compound 15 03 166 (90 094 714) or PVC tape - 50 Nm/36.88 lbf. ft.

       After cover has been screwed tight, distance between front of plate and surface of end shield must not exceed 4 mm/0.16 in., in order to obtain a certain sealing screw depth.

Bolt shift mechanism cover to main case - 22 Nm/16.23 lbf. ft.

Adjust transmission shift linkage (see operation in this group).

c) Seal for End Shield, Replace

(only F 20 - and all 5-speed manual transmissions as of MY 88 ½)

Raise vehicle.

Unbolt transmission cover from end shield.

Important: Oil escapes.

Unscrew fillister head screw from turbine shaft.

       Beforehand, remove snap ring.

       Mark installation position of transmission turbine shaft in gear cluster with paint.

Pull out transmission turbine shaft to stop using KM-556-1-A (previously KM-449-1 in conjunction with Kukko Counterstay 22-1) and Adapter KM-556-4.

       Clutch splines are disengaged. For this reason, do not actuate clutch after this point.

Unscrew reversing lamp switch.

Unbolt end shield from main case.

Withdraw end shield with main shaft and turbine shaft from main case.

       Important: Fluid escapes.

Replace end shield gasket.

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

Stick new seal to main case with antifriction bearing grease.

Screw in reversing lamp switch: 20 Nm/14.75 lbf. ft.

       By hand carefully insert or slip transmission drive shaft into splines of clutch disc and gear cluster (splines of both shafts must be seated in corresponding tooth gaps of clutch disc and gear cluster).

       Observe paint marks made on turbine shaft and gear cluster during removal.

Screw fillister head screw into transmission turbine shaft and press shaft into gear cluster as far as stop using KM-564.

Secure turbine shaft with snap ring.

       Use new snap ring.

Bolt transmission cover to end shield.

     Prescribed torque: M 7 x 1.0 = 15 Nm/11.06 lbf. ft.

                                   M 8 x 1.25= 20 Nm/14.75 lbf. ft.

Install reversing lamp switch - 20 Nm/14.75 lbf. ft.

Bolt shift mechanism cover to main case - 22 Nm/16.23 lbf. ft.

Adjust transmission shift linkage (see operation in this group).

Check transmission fluid and top up.

Transmission fluid is filled through opening for bleeder screw plug in shift cover.

Fluid level = lower edge of inspection aperture (except in F 20)

In F 20

In order to check the fluid level, construct an ad hoc tool (e.g. out of welding rod) as in diagram.

Fluid level = 5 mm/0.2 in. below inspection aperture

Inspection aperture on F 20 manual transmission, R.H. rear looking in direction of travel.