Vauxhall Workshop Service and Repair Manuals

 

End Shield, Assemble and Install (F 13/F 18/F 18+)     Install, Connect    Press reverse gear shaft to stop in end shield with lock ball inserted.   Install locking pins for gear lock in end shield bore hole (component 1 in assembly illustration J 0160 below).   With replacement of the shift fork or shift rod for 1st/2nd gear: Pin shift fork and shift rod for 1st/2nd gear - use KM-308/2. Allow new spring pin to project approx. 2 mm.

  Install, Connect   

Guide main shaft (1), drive shaft (4), 1st/2nd gear (2) and reverse gear (3) shift forks and shift rods into end shield.   Reverse gearshift fork groove points upwards. Lubricate return bore hole with Transmission Fluid.   Place thrust washer on axle of reverse gear wheel. Secure main shaft and drive shaft. Engage new retaining rings in grooves - use Retaining Ring Pliers KM-443-B.     1  Lock pin for gear stop   2  5th gear shift driver   3  Reverse gear shift fork   4  Reverse gear shift rod   5  3rd/4th gear shift rod   6  3rd/4th gear shift fork   7  1st/2nd gearshift fork and shift rod

  Install, Connect   

Insert reverse gearshift rod and shift fork, 3rd/4th gearshift rod and shift fork with 5th gearshift driver in end shield.   Support shift rods with block of wood.   Pin shift forks and shift rods with new spring pins - use KM-308.   With transmissions F 18/F 18+, the 5th gear shift driver for the gear set brake rocker arm has a longer design.   Press driver in 5th speed position, engage 2nd and 3rd gears and install bridge with locking pin at end shield (arrow).     Tighten (Torque)    Insert new bolts with locking compound - 7 Nm / 5 lbf. ft.

  Install, Connect   

Attach bearing support with pawl to end shield. Slot in 3rd/4th gear shift rod must align with pawl. Insert new bolts with screw locking compound (red).     Tighten (Torque)    Bearing support with pawl to end shield - 7 Nm / 5 lbf. ft.   Insert 2nd gear with shift sleeve.   Drive in 4 closure plugs (arrows) to stop with plastic mallet or soft metal drift.     Important!    Bore holes must be oil-tight, if necessary use oversize plugs.

  Install, Connect   

Place end shield assembly on KM-554.   Press 5th gear (driving) onto gear cluster using KM-466-3 so that long gear hub faces ball bearing. New retaining ring on gear cluster.   Thrust washer halves on main shaft. Retaining ring on thrust washer halves. Needle bearing on main shaft. Slide 5th gear onto needle bearing. Place synchroniser ring onto 5th gear cone.   Heat 5th speed synchromesh body to approx. 100 ° C/212 ° F and press on main shaft so that synchroniser spring faces gear - use KM-334.   New retaining ring on main shaft.

  Inspect   

Check thread for bearing support for ease of movement, recut M8 x 1.25 if necessary. Insert new bolts with screw locking compound (red).     Tighten (Torque)    Screw bearing support with pawl to end shield cover - 22 Nm / 16 lbf. ft.     Install, Connect    Install thrust washer for reverse gear wheel - Note installation position.

  Tighten (Torque)   

End shield assembly to transmission housing:   M7 x 1.0:   15 Nm / 11 lbf. ft.     M8 x 1.25:   20 Nm / 15 lbf. ft.         End shield cover to end shield:   M7 x 1.0:   15 Nm / 11 lbf. ft.     M8 x 1.25:   20 Nm / 15 lbf. ft.

  Install, Connect   

Only for F 18/F 18+: Insert rocker arm for gear set brake and secure with retainer pin.  

For all transmissions: Shift cover with new gasket to transmission - ensure that pin (arrow) engages (not for F 17).  

  Remove, Disconnect   

Remove transmission from KM-444-2 and KM-489.