Vauxhall Workshop Service and Repair Manuals

 

Reverse Idler Shaft, Disassemble and Reassemble (F 25)     Disassemble    Clamp reverse gear wheel in vice with protective jaws. Mark installation position of the reverse idler shaft in the reverse idler shaft support with marking pencil for identification.   Drive reverse idler shaft out of reverse idler shaft support with drift (1).     Important!    Ensure that no parts fall out when driving out reverse idler shaft.

  Disassemble   

Remove reverse idler shaft support (1), bearing disc (2), reverse gear (3), shift sleeve (4), spring ring (5), synchroniser ring (6), shifted reverse gear (7), needle bearing (8) from reverse idler shaft (9).     Inspect    Check all parts for wear and damage - damaged or defective parts must be replaced.     Measure    Measure wear of the synchroniser unit - to do this, fit synchroniser unit and measure at three points between synchroniser ring and shifted reverse gear (7) using feeler gauge and determine the average.   Average value less than 0.5 mm/0.02 in: replace synchroniser ring.

 

Before assembly, coat all parts with transmission fluid.     Assemble    Clamp reverse idler shaft (5) in vice with protective jaws. Place needle bearing (4) and reverse drive gear (3) on reverse idler shaft. Install synchroniser ring (2) - note seating of spring ring on synchroniser ring. Place shift sleeve (1) on synchromesh body - ensure that longer toothing of shift sleeve fits in deeper grooves of synchroniser hub. The longer toothing of the shift sleeve is installed downwards.   Install reverse drive gear with integrated synchroniser hub.     Important!    The recesses in the synchroniser hub must sit above the shoulders of the synchroniser rings (arrows).

  Assemble   

Position bearing disc (3) - ensuring that journal of bearing disc lies between stops of reverse idler shaft support (4). Press reverse idler shaft support onto reverse idler shaft according to marking. Use 17 mm/0.67 in. inner diameter sleeve (1) to press in - counterhold with 19 mm/0.75 in. inner diameter sleeve (2).     Important!    The screw hole of the reverse idler shaft support must lie on a line with lubrication aperture of reverse idler shaft. Insert a bolt through reverse idler shaft support into reverse idler shaft, to check whether opening of reverse idler shaft aligns with opening in reverse idler shaft support.     Measure    Check the correct assembly of the reverse gear. Measure the clearance between reverse gear and bearing disc using feeler gauge. The axial clearance must be 0.10 mm - 0.20 mm. Try shifting the reverse gear by pressing down the shift sleeve.