Vauxhall Workshop Service and Repair Manuals

Main Shaft, Assemble

All synchromesh bodies, sliding blocks, synchronizer rings and spacers are interchangeable.

Assemble both synchromesh bodies, 1st and 2nd gears, as well as 3rd and 4th gears.

See illustration C 9906 at beginning of operation "Manual Transmission and Differential, Overhaul" for arrangement of 3-cone synchronization.

Attach synchronizer springs oppositely directed with hooks in the same sliding block so that free end of each spring protrudes from the synchromesh body.

Seat each sliding block in flat centre tooth of sliding sleeve.

Slide 3rd gear onto main shaft from drive shaft end.

Coat bearing bore with Transmission Fluid 19 40 750 (90 001 777).

Place synchronizer ring on cone of 3rd gear.

Press assembled synchromesh body for 3rd and 4th gear into place with KM - 277.

Preheat assembled synchromesh body to 100 °C/212 °F.

(use thermocolour pencils or suitable temperature gauge).

Coat seating surface on main shaft with Transmission Fluid 19 40 750 (90 001 777). Secure synchromesh body with new retaining ring.

Slide synchronizer ring and 4th gear onto main shaft.

Press on spacing washer with KM-334 and drive gear (driving) with KM - 31112.

Preheat both parts to 100 °C/212 °F (use thermocolour pencils or suitable temperature gauge).

Coat seating surfaces on main shaft with Transmission Fluid 19 40 750 (90 001 777).

The grooves of the spacing washer face the gear.

Always replace the driving and driven gears in pairs.

- Note groove marks (groove extending around on tip of tooth) (see Technical Data).

Front surface of main shaft gear with collar faces spacing washer.

Secure main shaft gear with new retaining ring.

Slide 2nd gear onto main shaft.

Coat bearing bore with Transmission Fluid 19 40 750 (90 001 777).

Place synchronizer ring on cone of 2nd gear.

Press on assembled synchromesh body of 1st and 2nd gear with KM - 277 (S - 1276).

Preheat assembled synchromesh body to 100 °C/212 °F (use thermocolour pencils or suitable temperature gauge).

Shift fork groove faces ball bearing seat.

Coat seat on main shaft with Transmission Fluid 19 40 750 (90 001 777).

With 3-cone synchronization, the hooks of the inner synchronizer rings must lie in the recesses of the outer rings.

Secure synchromesh body with new retaining ring.

Slide synchronizer ring and 1st gear onto main shaft.

For F 13 and F 10 as of Model Year '86: place thrust bearing assembly in front of 1st gear cluster.

Press on spacing washer and ball bearing with KM-311/2; for F 13, use KM - 334.

Beforehand, add new retaining ring with long ends (for main shaft at end shield).

Preheat spacing washer to 100 °C/212 °F

(use thermocolour pencils orsuitable temperature gauge).

The grooves of the spacing washer face the gear.

Coat seat of spacing washer on main shaft with Transmission Fluid 19 40 750 (90 001 777).

Secure ball bearing with new retaining ring.