Vauxhall Workshop Service and Repair Manuals

End Shield, Disassemble and Assemble (F 17)

Note:   Transmission remains installed.

  Remove

1.   Remove shift mechanism cover (1) 2.   Remove reversing lamps switch (2). 3.   Remove end shield cover (3) 4.   Remove end shield (4) from transmission

5.   Attach end shield to KM-552 (2) •   Attach KM-552 to KM-113-2 (1) 6.   Remove bearing block (6) with pivoting lever (7) from end shield •   Unscrew 2x bolt Note:   Microencapsulated bolts. If the bolts are difficult to move, heat the end shield to approx. 80°C with an industrial hot-air blower. 7.   Remove both needle cages for 5th gearwheel •   Detach retaining ring (8) from synchro body •   Remove 5th gear synchro body (4) with 5th gear gearwheel (5) from main shaft Note:   If it is difficult to move, use KM-161-B (3).

8.   Remove retaining ring (1) of 5th speed gear (driving) (2) from drive shaft (3) 9.   Pull 5th gear gearwheel (driving) from drive shaft with KM-553-A •   Place thrust piece (5) from KM-553-A (6) onto drive shaft Note:   Ensure KM-553-A is correctly seated on the gear wheel, 5th gear (driving) 10.   Remove bearing block (7) with latch (6) from end shield •   Unscrew 2x bolt (arrow) Note:   Microencapsulated bolts. If the bolts are difficult to move, heat the end shield to approx. 80°C with an industrial hot-air blower.

11.   Remove locking plug (arrows) from end shield with KM-727 (2) and KM-328-B (1) 12.   Detach 2 bolts (4) from bridge (3) for locking bolt from end shield Note:   Microencapsulated bolts. If the bolts are difficult to move, heat the end shield to approx. 80°C with an industrial hot-air blower. 13.   Engage 2nd gear and 5th gear (with shift driver) Note:   The bridge will push itself out when 3rd gear is subsequently engaged.

14.   Remove roll pins (arrows) with KM-308 Note:   Relieve pressure on shifter rod guides – for this, support shifter rods above with wood (1). •   Drive out of 3rd/4th gear shift fork (3) •   Drive out of reverse gear shift fork (6) 15.   Remove 3rd, 4th (3) and reverse gear (6) shifter rods (2) and shift forks from end shield 16.   Remove 5th gear shift driver (4) from end shield 17.   Remove locking pin (5) for catch from end shield hole

18.   Remove retaining springs for main shaft (2) and drive shaft (5) from grooves of end shield with KM-443-B (6) Note:   To assist when dismantling, keep the retaining ring for the main shaft under tension with fitting plate (1). 19.   Remove main shaft (2) from end shield 20.   Remove drive shaft (5) from end shield 21.   Remove reverse idler (8) from end shield. 22.   Remove shift fork (4) and gearshift rod 1st/2nd (3) gear from end shield. 23.   Remove reverse gear wheel (7) •   Clamp in vice with protective jaws •   Carefully knock out end shield with brass drift Note:   Note that retaining ball is released.

  Install

27.   Push reverse gearwheel axis into end shield as far as it will go •   Insert retaining ball (arrow) Note:   Note installation position.

28.   Coat bearing and reverse bore hole with transmission fluid 29.   Insert main shaft (2), drive shaft (1), reverse gear wheel (5) and shift fork (4) with 1st/2nd gear shift rod (3) into end shield Note:   Shift fork groove (arrow) for reverse idler gear (5) points upwards. •   Secure with new retaining rings •   Insert retaining rings with KM-443-B Note:   Retaining rings must engage correctly in grooves.

30.   Insert 3rd/4th reverse gear locking pin (1) 31.   Insert shift fork (5) and reverse gear shift rod (6) Note:   To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin. •   Pin with KM-308 (4) 32.   Allow new locating pin to protrude by approx. 2 mm (Dimension I). 33.   Insert shift fork (3) and shift rod (2) for 1st/2nd gear •   Pin with KM-308 (4)

34.   Insert 5th gear shift driver (4) 35.   Insert gear shift fork (2) and shift rod (1) for 3rd/4th gear Note:   To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin. •   Pin with KM-308 (3) 36.   Fit locking plugs (5), (6) and (7) •   Drive 4 locking plugs in as far as they will go with plastic hammer or soft metal drift 37.   Bring shift fork into neutral position.

39.   Coat 2 new bolts (1) with locking compound 40.   Place bridge for locking bolt onto end shield (2) •   Tighten 2 bolts slightly •   Move gearshift fork 1st/2nd gear into neutral •   Tighten 2 bolts 7 Nm 41.   Bring shift fork into neutral position. 42.   Coat 2 new bolts (arrow) with locking compound 43.   Fit bearing block (4) with latch (3) to end shield •   Tighten 2 bolts 7 Nm

45.   Insert end shield with main and drive shaft into KM-554 (2) 46.   Press on gearwheel for 5th gear (driving) with KM-514 (1) Note:   Long gear hub points to end shield. 47.   Install new retaining ring (3) 48.   Attach end shield with KM-552 to KM-113-2 49.   Place needle bearings (5) for 5th gear gearwheel (4) onto main shaft •   Coat 2x needle bearing with transmission fluid Note:   Ensure that the slotted needle bearing is correctly seated

51.   Slide 5th gear gearwheel (2) and synchro body (1) onto main shaft Note:   Secure with new retaining ring (3) 52.   Insert crosshead shoe (arrow) in 5th gear shift fork (4). 53.   Coat new bolts with locking compound 54.   Attach bearing bracket to end shield with pivoting lever •   Tighten 2x bolt 22 Nm

55.   Fit friction washer (arrow) on reverse gear shaft •   Stick on friction washer with grease

57.   Install end shield (1) in transmission 58.   Install end shield cover (2) gasket 59.   Install reversing lamp switch (4) with new seal ring •   Tighten switch 20 Nm 60.   Install gearshift cover (3) 61.   Check transmission fluid level