Vauxhall Workshop Service and Repair Manuals

Main Shaft, Disassemble and Assemble (F 13)  

Illustration  

Notice: 

Provision of the main shaft with needle bearings for the gears may deviate from the example shown here.  

 

1  Retaining ring   2  Drive gear (driving)   3  Spacer washer   4  4th speed gear   5  4th gear synchroniser ring   6  Retaining ring   7  3rd/4th gear shift sleeve   8  Synchroniser spring   9  Sliding block   10  Synchromesh body   11  Synchroniser spring   12  3rd gear synchroniser ring   13  3rd speed gear   14  Main shaft

Illustration (Continued)  

15   2nd speed gear   16   Inner synchroniser ring   17   Intermediate ring   18   Outer synchroniser ring   19   1st/2nd gear shift sleeve   20   Synchroniser spring   21   Sliding block   22   Synchromesh body   23   Synchroniser spring   24   Retaining ring   25   Outer synchroniser ring   26   Intermediate ring   27   Inner synchroniser ring   28   1st speed gear   29   1st gear needle bearing   30   Axial needle bearing   31   Thrust washer   32   Retaining ring   33   Ball bearing

Notice: 

Transmission remains installed.  

  Remove, Disconnect   

Remove cover (1) for shift mechanism - see operation "Cover for Shift Mechanism, Remove and Install and / or Seal".   Remove reversing lamps switch (2).   Remove gasket for end shield cover (3) - see operation "Gasket for End Shield Cover, Replace".   Remove end shield (4) from transmission - see operation "Gasket for End Shield, Replace".

  Remove, Disconnect   

Remove main shaft - see operation "End Shield, Disassemble and Assemble (F 13)".   Notice:  If the gears are damaged, always also replace the gear cluster.     Disassemble    Press off ball bearing (3), spacer washer (4), retaining ring (6), output shaft (5) and gearwheel for 1st gear (7) with suitable drift (1) in conjunction with KM-307-B (2).   Remove needle bearing (8) for 1st gear from main shaft.   Remove inner synchroniser ring (9), intermediate ring (10) and outer synchroniser ring (11) for 1st gear from synchromesh body assembly (12).

  Disassemble   

Remove retaining ring for 1st/2nd gear synchromesh body assembly (1) with ring pliers (2).   Remove shifter collar (7), synchroniser spring (6) and slide blocks (3 and 5) from synchromesh body (4).   Press off synchromesh body (8), inner synchroniser ring (9), intermediate ring (10) and outer synchroniser ring (11) for 2nd gear, and for 2nd gear (12) with suitable drift (13) from main shaft in conjunction with KM-307-B (14).

  Disassemble   

Remove retaining ring (1) in front of drive gear (driving) from main shaft.   Press of drive gear (driving) (3) with suitable drift (2) from main shaft in conjunction with KM-307-B (4).     Important!    Always replace drive gears (driving and driven) in pairs

  Disassemble   

Place KM-307-B (1) in groove of 4th gear (2).   Press off 4th gear and spacer washer (4) with suitable drift (3) from main shaft in conjunction with KM-307-B.   Remove needle bearing (5) (if in place), synchroniser ring (4th gear) (6), shifter collar (7), synchroniser spring and slide blocks from main shaft.   Press off synchromesh body (9) 3rd/4th gear, synchroniser ring and 3rd gear (10) with suitable drift (8) from main shaft in conjunction with KM-307-B.

  Clean   

Clean all parts.     Inspect    Immerse all parts in transmission fluid before installation.   Check all removed parts for damage and wear, replace if necessary.   Lubricate all bearing bore holes and seating surfaces with transmission fluid before installation.   Transmission has 3 cone synchronisation for 1st/2nd gear:     1  2nd speed gear   2  Inner synchroniser rings   3  Intermediate rings   4  Outer synchroniser rings   5  shift sleeve   6  Synchroniser springs   7  Sliders   8  Synchromesh body   9  1st speed gear

 

Notice:  Synchromesh body assembly 1st/2nd gear and 3rd/4th gear can only be pressed onto main shaft in assembled state.     Assemble    Insert synchromesh body (3) into shifter collar (2).   Insert slide blocks (1 and 5) with the open end toward synchromesh body.   Insert synchroniser spring (4); ensure that the correct end of synchromesh body raises (arrow) for correct installation position.   If this is not the case, turn synchroniser spring 180 ° and reinstall.   Offset end of synchroniser engages in a slide block.

  Assemble   

If present: Attach needle bearing (2) for 3rd gear to main shaft (1).   Push 3rd gear (3) onto main shaft from drive gear side so that cone (arrow) points towards the drive gear.   Place synchroniser ring (4) onto 3rd gear cone.   Press synchromesh body assembly for 3rd/4th gear (6) with KM-277 (5) onto main shaft.

  Assemble   

If present: Attach needle bearing for 4th gear to main shaft.   Attach synchroniser ring (3) and 4th gear (2) to main shaft.   Place spacer washer (1) on main shaft with four grooves (arrows) pointing towards 4th gear.   Press drive gear (5) onto main shaft so that collar faces spacer washer - use KM-311/2 (4).   Insert new retaining ring (6) in front of drive gear.   Notice:  Always replace drive gears in pairs.

  Assemble   

Push 2nd speed gear (4) onto main shaft.   Place synchroniser ring (3) onto gear cone so that lugs are located in the grooves of the gear.   Place intermediate ring (2) on inner synchroniser ring.   Place outer synchroniser ring (1) onto intermediate ring so that grooves are seated on lugs of inner synchroniser ring.   Place synchromesh body assembly (5) on main shaft.   Press synchromesh body assembly with KM-277 (6) onto main shaft so that lugs of outer synchroniser ring align with grooves in synchromesh body. Groove (arrow) of shift fork points towards ball bearing seat.   Insert new retaining ring (8) for 1st/2nd gear synchromesh body with ring pliers (7).

  Assemble   

Place outer synchroniser ring (3) with lugs in grooves of synchromesh body (4).   Place intermediate ring (2) on outer synchroniser ring.   Place inner synchroniser ring (1) onto intermediate ring so that lugs engage in grooves of outer synchroniser ring.   If present: Position 1st gear needle bearing (5) on main shaft. Push first speed gear onto needle bearing so that the grooves are seated on the lugs of the intermediate ring.   Place output shaft (8) on 1st speed gear (10). Set spacer washer (7) on needle bearing.   Place new retaining ring (9) with long legs (for main shaft to end shield) on 1st speed gear. Press ball bearing (6) onto main shaft with KM-334 (11).

  Inspect   

All speed gears must easily be turned.     Install, Connect    Install main shaft - see operation "End Shield, Disassemble and Assemble (F 13)".   Install end shield (1) in transmission - see operation "Gasket for End Shield, Replace".   Install end shield cover (2) - see operation "Gasket for End Shield Cover, Replace".   Install reversing lamps switch (4) with new seal ring - tightening torque 20 Nm / 15 lbf. ft.   Install cover (3) for shift mechanism - see operation "Cover for Shift Mechanism, Remove and Install and / or Seal".