vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

Transmission Housing, Replace (F13) > < Clutch Disc, Pressure Plate, Clutch Thrust Bearing and/or Release Lever, Remove and Install

 

Synchroniser Rings, Remove and Install (F 13)  

Notice: 

Transmission remains installed.  

Object Number: 616191  Size: DEFAULT  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 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".  

Object Number: 2415624  Size: DEFAULT

 

 

Object Number: 616191  Size: DEFAULT  Remove, Disconnect   

Remove main shaft - see operation "End Shield, Disassemble and Assemble (F 13)".  

Disassemble main shaft - see operation "Main Shaft, Disassemble and Assemble (F 13)".  

Object Number: 616196  Size: DEFAULT  Inspect   

Replace affected synchroniser rings:  

 

1  4th gear synchroniser ring  

2  3rd gear synchroniser ring  

3  1st gear inner synchroniser ring  

4  1st gear intermediate ring  

5  1st gear outer synchroniser ring  

6  2nd gear outer synchroniser ring  

7  2nd gear intermediate ring  

8  2nd gear inner synchroniser ring  

 

Object Number: 2414150  Size: DEFAULT

 

 

Notice: 

If a synchromesh body assembly has been completely disassembled then the following method of procedure shall be observed for assembly.  

Object Number: 616194  Size: DEFAULT  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.  

Object Number: 2414066  Size: DEFAULT

 

 

Notice: 

Fifth speed gear synchroniser ring is removed and installed within the scope of the operation "End Shield, Disassemble and Assemble (F 13)".  

Object Number: 616192  Size: DEFAULT  Install, Connect   

Assemble main shaft - see operation "Main Shaft, Disassemble and Assemble (F 13)".  

Install main shaft - see operation "End Shield, Disassemble and Assemble (F 13)".  

 

 

Object Number: 616192  Size: DEFAULT  Install, Connect   

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".  

Object Number: 616196  Size: DEFAULT  Inspect   

Check transmission fluid level - see operation "Transmission Fluid Level, Check".  

Object Number: 2415623  Size: DEFAULT

 

 


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Transmission Housing, Replace (F13) > < Clutch Disc, Pressure Plate, Clutch Thrust Bearing and/or Release Lever, Remove and Install