Vauxhall Workshop Service and Repair Manuals

Differential Transmission, Disassemble and Assemble (F 15/F 17)  

Notice: 

Transmission remains installed.  

  Remove, Disconnect   

Remove axle shafts (1) - see operation "Axle Shafts, Remove and Install" in group "E".   Remove end shield cover (2) - see operation "Gasket for End Shield Cover, Replace (F 13/F 15/F 17/F 18/F 18+)".   Remove end shield (3) from transmission casing - see operation "Gasket for End Shield, Replace (F 13/F 15/F 17/F 18/F 18+)".   Remove differential (4) - see operation "Differential, Remove and Install (F 13/F 15/F 17/F 18/F 18+)".

  Disassemble   

Remove seal ring from bearing ring (3) and from transmission with K-454-2 (1) and KM-454-4 (2).   Only necessary if bearings are replaced in bearing ring: Remove outer race of tapered roller bearing from bearing ring with KM-304 (4) and KM-451 (5). Place KM-303 (6) underneath.   Remove outer race of tapered roller bearing from transmission - use KM-305 and KM-451. With removed transmission, use KM-304 and KM-451.

  Disassemble   

Only required when replacing: Remove both tapered roller bearing inner races (1) using KM-161-B (2), KM-161-3 (4) and KM-161-4 (3).   Notice:  Do not interchange outer and inner races respectively when re-using tapered roller bearings.   For overhauling work, the speedometer gear (driving) (5) should be destroyed, if still present. On assembling, it is not reinstalled.     Disassemble    Clamp differential housing in vice with protective jaws. Remove drive gear from differential housing.

  Important!   

Replace drive gears (1) only in pairs (driving and driven). Observe running groove markings (arrows) at gear head - see "Survey" in chapter "Technical data".     Disassemble    Only required when replacing: Remove retaining rings (2) from bevel gear shaft. Remove bevel gear shaft.   Unscrew axle shaft and differential pinions with KM-458-A. Remove plastic cage.

  Clean   

Clean all removed parts and transmission housing.  

  Inspect   

Check removed parts for signs of scoring and damage; if necessary replace. Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid.  

  Assemble   

Install plastic cage in differential housing.  

  Important!   

Collar (1) of plastic cage must sit in guide for axle shaft bevel gears in housing.     Assemble    Insert / screw out axle shaft bevel gears and differential bevel gears in differential housing.   Clamp differential housing with KM-458-A (3) in vice with protective jaws.   Centre differential bevel gears using KM-456 (2).   Install bevel gear axle (6) and secure with new retaining rings (4 and 5).

  Assemble   

Attach drive gear (1) with new fastening bolts to vehicle differential housing - tightening torque 80 Nm / 59 lbf. ft.   Notice:  Replace drive gears only in pairs (driving and driven). Observe running groove markings (arrows) at gear head - see "Survey" in chapter "Technical data".     Assemble    Press inner races of tapered roller bearings (3) onto differential housing (4) using KM-453 (2).

  Install, Connect   

Install tapered roller bearing outer race (2) with KM-304 (1) and KM-451 (3) in transmission and/or bearing ring.   Drive new axle shaft seal ring into bearing flange with KM-446 - see operation "Axle Shaft Seal Rings, Replace".   Install differential (4) - see operation "Differential, Remove and Install (F 13/F 15/F 17/F 18/F 18+)".   Install end shield (3) - see operation "Gasket for End Shield, Replace (F 13/F 15/F 17/F 18/F 18+)".   Install end shield cover (2) - see operation "Gasket for End Shield, Replace (F 13/F 15/F 17/F 18/F 18+)".   Install axle shafts - see operation "Axle Shafts, Remove and Install" in group "E".