Vauxhall Workshop Service and Repair Manuals

Main shaft, dismantle and reassemble (F13+/F13+ MTA)

Note:   Transmission remains installed.

Overview main shaft

  Remove

2.   Remove main shaft Note:   In case of damage to the gear wheels, always replace the toothed gear block as well. 3.   Press out distance washer (3), axial needle bearing (4) and gear wheel 1st gear (5) with KM-307-B (2) •   Use fitting driver (1) 4.   Remove needle bearing (10) for gear wheel 1st gear from main shaft Note:   If present. 5.   Remove inside synchronising ring (6), intermediate ring (7) and outside synchronising ring (8) for gear wheel 1st gear from synchroniser body assembly (9)

6.   Remove lock ring for synchroniser body assembly (1) 1st/2nd gear with lock ring pliers (2) KM-396 7.   Remove synchronising spring (6), synchroniser sleeve (7) and sliders (3 and 5) from synchroniser body (4) 8.   Press synchroniser body (14), inside synchronising ring, (13), intermediate ring (12) and outside synchronising ring (11) for gear wheel 2nd gear (10) out with KM-307-B (9) from main shaft (arrow) •   Use fitting driver (8)

9.   Remove lock ring (1) in front of drive wheel (driving) from main shaft 10.   Press drive wheel (driving (3) out with KM-307-B (4) from main shaft (arrow) Note:   Always replace drive wheels (driving and driven) in pairs. •   Use fitting driver (2)

11.   Place KM-307-B (1) in the groove of the gear wheel 4th gear (2) 12.   Press gear wheel 4th gear and distance washer (4) out with KM-307-B from main shaft •   Use fitting driver (3) 13.   Remove needle bearing (11) (if present), synchronising ring (gear wheel 4th gear) (10), synchroniser sleeve (9), synchronising spring and sliders from main shaft 14.   Remove lock ring (6) with lock ring pliers 15.   Press synchroniser body (7) 3rd/4th gear, synchronising ring and gear wheel 3rd gear (8) out with KM-307-B from main shaft •   Use fitting driver (5)

  Install

16.   Clean all parts 17.   Dip all parts in transmission oil before installation 18.   Check removed parts for damage, wear; replace if necessary 19.   Lubricate all bearing holes and seating surfaces with transmission oil before installation 20.   Transmission has a 3-cone synchronisation for the 1st and 2nd gear: 1. Gear wheel 2nd gear 2. Inside synchronising rings 3. Intermediate rings 4. Outside synchronising rings 5. Synchroniser sleeve 6. Synchronising springs 7. Sliders 8. Synchroniser body 9. Gear wheel 1st gear

21.   Insert synchroniser body (3) in synchroniser sleeve (2) Note:   Assembly of synchroniser bodies 1st/2nd gear and 3rd/4th gear can only be pressed onto the main shaft in the assembled state. 22.   Insert sliders (1) and (5) •   with the open side to the synchroniser body 23.   Insert 2x synchronising spring (4) Note:   Ensure that with correct installation position, the free end of the synchronising spring lifts up from the synchroniser body (arrow). If this is not the case, turn synchronising spring 180° and reinstall. •   The bent end of the synchronising spring engages with a slider

24.   Install needle bearing (2) for gear wheel 3rd gear on main shaft (1) Note:   If present. 25.   Move gear wheel 3rd gear (4) from drive wheel side to main shaft •   Cone (arrow) points in the direction of the drive wheel 26.   Place synchronising ring (3) on cone gear wheel 3rd gear 27.   Press assembly of synchroniser body 3rd/4th gear (6) with KM-373-1 (5) on main shaft 28.   Mount synchroniser body lock ring (7) with KM-396 29.   Install needle bearing (8) for gear wheel 4th gear on main shaft Note:   If present.

30.   Install synchronising ring (3) and gear wheel 4th gear (2) on main shaft 31.   Place distance washer (1) on main shaft •   Four grooves (arrow) must point to gear wheel 4th gear 32.   Press drive wheel (5) onto main shaft with KM-473 (4) Note:   Always replace drive wheels in pairs. •   Collar must point to distance washer 33.   Install new lock ring (6) in front of drive wheel

34.   Move gear wheel 2nd gear (4) onto drive shaft 35.   Place inner synchronising ring (3) on cone of gear wheel •   Noses must sit in grooves of gear wheel 36.   Place intermediate ring (2) on inner synchronising ring 37.   Place outer synchronising ring (1) on intermediate ring •   Grooves must sit on noses of inner synchronising ring 38.   Place synchroniser body assembly (5) on main shaft 39.   Press synchroniser body assembly onto main shaft with KM-514 (8) •   Noses of outer synchronising ring must be aligned with grooves of synchroniser body •   Shift fork groove (arrow) points to ball bearing seat 40.   Insert new lock ring (7) with lock ring pliers (6) in front of synchroniser body 1st/2nd gear

41.   Place outer synchronizing ring (3) with noses in grooves of synchroniser body (4) 42.   Place intermediate ring (2) on the outer synchronising ring 43.   Place inner synchronising ring (1) on intermediate ring •   Noses must engage in grooves of outer synchronising ring 44.   Place needle bearing 1st gear (5) on main shaft Note:   If present. 45.   Move gear wheel 1st gear onto needle bearing •   Grooves must sit on noses of intermediate ring 46.   Place axial needle bearing (8) on gear wheel 1st gear (7) •   Place distance washer (9) on needle bearing 47.   Press distance washer onto main shaft with KM-473 (6)