Vauxhall Workshop Service and Repair Manuals

Disassemble transmission – see operation "Transmission, Disassemble and Assemble".

Auxiliary shaft gear cluster from main shaft.

Main drive gear (1) with synchroniser ring of 4th gear (2) and needle roller bearing (3) from main shaft.

Clamp main shaft in vice – use protective jaws, drive side of main shaft (without thread attachment) faces upwards.

Retaining ring from main shaft, retaining ring pliers.

Press 3rd/4th synchromesh body (1), synchroniser ring, 3rd gear (2) and needle roller bearing from main shaft, KM-307-B. Push KM-307-B under 3rd gear.

Press off main shaft.

Clamp main shaft in vice with drive side upwards.

Retaining ring (1) and both thrust washer halves (2) from main shaft.

2nd gear (1) with 3 cone synchromesh unit from main shaft, needle roller bearing (2) from main shaft.

Retaining ring for 1st/2nd synchromesh body from main shaft using retaining ring pliers.

Press off synchromesh body, 3 cone synchromesh unit, 1st gear by placing 1st gear on 2 flat irons.

Ball bearing of main shaft – KM-307-B. Push KM-307-B under bearing as far as possible and press main shaft off bearing.

Caution

Align retaining ring to bearing outer ring and attach while pressing off.

Clamp main shaft in vice with drive side upwards.

5th gear from main shaft.

Slotted needle roller bearing for 5th gear from main shaft, unhook needle roller bearing and spread carefully.

Retaining ring for 5th/reverse synchromesh body from main shaft.

Press off 5th/reverse synchromesh body, synchroniser ring and reverse gear from main shaft using KM-307-B.

Caution

Do not use recess of main shaft behind synchromesh body as support.

  Remove

Slotted needle roller bearing for reverse gear from main shaft, unhook needle roller bearing and spread carefully.

Lever seal ring (1) out of from main drive gear.

Needle roller bearing and, if present, spacer from main drive gear.

  Inspect

Removed parts for damage and wear.

Caution

If auxiliary shaft gear cluster or the gears are damaged, replacement of the whole gear cluster is recommended to avoid running noises.

Before assembling the main shaft, complete synchromesh bodies. Only one version is described on the following pages since this operation is the same for all synchromesh bodies. Identification and special installation position of the respective synchromesh bodies are indicated in the assembly of the main shaft.

1st/2nd synchromesh body, identification: 1 groove (arrow) on shift sleeve, overall width (1) is 24.0 mm/0.94 in.

Do not mix up sliding blocks.

Different sliding blocks are used for the 3rd/4th synchromesh body and 5th/reverse (1, ball-type version) than for the 1st/2nd synchromesh body (2, narrow version).

3rd/4th gear synchromesh body:

Identification: 2 grooves (1) on shift sleeve, small diameter at inner teeth of synchromesh bodies.

The 4th gear synchroniser spring is interlaced by 10 mm/0.4 in. (3). Interlacing points away from contact surface. The sliding blocks (2) are opposite the counterbore (1).

5th/reverse synchromesh body:

Identification: 3 grooves (1) on shift sleeve, the sliding blocks (2) are opposite the counterbore (3).

Synchromesh body

Push shift sleeve onto synchromesh body, insert sliding blocks in slots in synchromesh body (arrow, bottom).

Caution

Notches on shift sleeve (arrow, top) and raised collar of synchromesh bodies point in one direction.

Install synchroniser springs.

Both springs of one synchromesh body are seated in the same sliding block, but face opposite directions.

Caution

Synchroniser spring of 4th gear is interlaced. Interlacing is 10 mm. The loose end of the spring points away from contact surface.

Clamp main shaft in vice using soft jaws (output side upwards).

Needle roller bearing (slotted version), reverse gear and molybdenum-coated synchroniser ring to main shaft.

Heat pre-installed synchromesh body reverse gear/5th gear to approx. 100 °C – use thermocolour pencils or suitable temperature gauge. Press synchromesh body onto main shaft – identification grooves point to the previously installed reverse gear wheel (raised belt of the synchromesh body points upwards). Only install 5th gear synchroniser ring after pressing on, so that this is not damaged when pressing the synchromesh body in.

When pressing into position, ensure that sliding blocks are inserted into recesses (1) of synchroniser ring. If necessary, lever up synchroniser rings slightly using screwdriver, so that they are seated freely on cone of gear (do not jam). If necessary, align sliding blocks and recesses by turning on the reverse gear.

Retaining ring for synchromesh body to main shaft, retaining ring pliers. Ensure it is correctly seated in groove.

Needle roller bearing for 5th gear to main shaft – spread slightly and mount over shoulder on main shaft.

5th synchroniser ring (arrow) to main shaft, 5th gear to main shaft.

Put on retaining ring (3) for rear main shaft bearing (1), tension using KM-627-1-A (4) and put on behind 5th gear. Push main shaft bearing (1) onto main shaft and press main shaft into bearing.

Caution

When pressing bearing on, ensure that recesses of synchroniser ring (2) are pressed exactly over sliding blocks of synchromesh body. If necessary, turn 5th gear.

Clamp main shaft in vice with output side downwards.

Axial needle roller bearing (1) and radial needle roller bearing (2) to main shaft.

1st gear to main shaft.

Attach 3 cone synchromesh unit to 1st gear (1).

Align lugs with the appropriate recesses. Note that these are sometimes on the inside (2) and sometimes on the outside of the synchroniser rings (3).

Heat pre-installed 1st/2nd synchromesh body to approx. 100 °C/212 °F, use thermocolour pencils or suitable temperature gauge. Press synchromesh body onto main shaft, identification groove of shift sleeve (arrow) points to input side of main shaft.

Caution

The sliding blocks must be seated in respective recesses of synchroniser ring. If necessary, align by turning 1st gear.

Retaining ring for synchromesh body to main shaft, retaining ring pliers. Ensure it is correctly seated in groove.

Needle bearing (2), synchromesh body cone (3) and 2nd gear (1) on main shaft.

See also Illustration D 2847 when completing 1st gear.

Insert 2 thrust washer halves with lugs into main shaft. Secure thrust washer halves with retaining ring.

Needle bearing (1), synchroniser ring (3) and 3rd gear (2) on main shaft.

Heat pre-installed 3rd/4th gear synchromesh body to approx. 100 °C/212 °F – use thermocolour pencils or suitable temperature gauge. Press synchromesh body onto main shaft – identification groove (arrow) of shift sleeve points to drive side of main shaft.

Caution

Press 3rd gear upwards using screwdriver, so that 3rd synchroniser ring is not jammed during pressing on.

Retaining ring for 3rd gear to main shaft. Install 4th synchroniser ring only after pressing on.

Grease new needle bearing and if available, place in main drive gear with spacer washer.

Press seal ring in flush to main drive gear using suitable sleeve.

Closed side of seal ring faces towards needle roller bearing.

Assemble transmission, see operation "Transmission, Disassemble and Assemble".