Vauxhall Workshop Service and Repair Manuals

End Shield, Dismantle and Assemble (F17+)

Note:   Transmission remains installed.

  Remove

1.   Remove shift mechanism cover (1) •   see operation "Gearshift Cover, Remove and Install and/or Seal (F13/F17/F17+/F18)" 2.   Remove reversing lamp switch (2) •   Disconnect reversing lamp (3) switch wiring harness plug •   Unscrew reversing lamp switch 3.   Remove end shield (4) cover •   See operation "Gasket for End Shield Cover, Replace (F13/F17/F17+/F18)". 4.   Remove end shield (5) •   See operation "Gasket for End Shield, Replace (F13/F17/F17+/F18)".

5.   Attach end shield to KM-113-2 •   Attach end shield to KM-552 (2) •   Attach end shield to KM-113-2 (1) using KM-552 Important:   Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield with hot-air dryer to approximately 80 °C. 6.   Remove bearing support (3) with rocker arm (4) from end shield •   Remove 2x bolts (6) 7.   Remove 5th gear (driven) •   Detach retainer (5) from synchro body •   Pull off 5th gear and synchromesh body 5th gear from main shaft using KM-559-A (8) •   remove needle cages for 5th gear

Important:   Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield with hot-air dryer to approximately 80 °C. 8.   Remove bearing support (2) with pawl (1) from end shield •   Remove 2x bolts (arrow) 9.   Engage 2 gears •   Engage reverse gear and 4th gear to block transmission 10.   Remove 5th gear (driven) (5) •   Remove retaining ring (7) from drive shaft (6) •   Locate KM-553-A (4) with thrust piece (3) on drive shaft and gear Note:   Check for proper seating •   Pull off 5th gear from main shaft using KM-553-A

11.   Remove locking plugs (arrow) •   Pull plug out of end shield using KM-727 (2) and KM-328-B (1) Important:   Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield with hot-air dryer to approximately 80 °C. 12.   Remove bridge for lock pin (3) •   Remove 2x bolts (4) Note:   Turn end shield onto its side •   Engage 2nd and 5th gears (with shift driver) •   Engage 3rd gear and remove bridge

Important:   Relieve pressure on shifter rod guides – for this, support shifter rods above with wood (1) 13.   Remove shift fork, 3rd/4th gear and reverse gear •   Drive roll pins out of 3rd/4th gear shift fork (3) and reverse gear shift fork (6) using KM-308 •   Take out shift rod (2), shift rod reverse gear and shift fork 14.   Remove gear shift driver •   Remove 5th gear shift driver (4) from end shield 15.   Remove locking pins (5) •   Remove roll pin for catch from end shield

Important:   Relieve pressure on shifter rod guides – for this, support shifter rods (1) above with wooden wedge (2) 16.   Remove 1st/2nd gear shift fork •   Drive roll pin (3) out of 1st/2nd gear shift fork (4) using KM-308 •   Take out shift fork with shift rod

Important:   Collect main shaft, drive shaft and reverse idler. 17.   Remove main shaft and drive shaft •   Detach end shield from KM-552 •   Press main shaft and drive shaft out as shown using KM-6335 (1) Note:   To ensure that both shafts are pushed out evenly, press harder on the main shaft side. Take care that the 1st gear wheel is not in contact with the press. •   Collect main shaft, drive shaft and reverse idler

Important:   Note that retaining ball is released. 18.   Remove reverse gear axle (1) •   Clamp reverse gear in vice with protective jaws •   Carefully knock off end shield with brass punch 19.   Remove bearing for main and drive shafts •   Remove 2x retaining rings (2) •   Press out 2x bearings using KM-500-5 (3)

  Install

Important:   Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid. 22.   Install bearing for main and drive shafts •   Press in 2x bearings using KM-523-1 (1) and KM-6336 (2) •   Fit 2x retaining rings (3) Note:   Check retaining ring for proper seating.

Important:   Check shaft for proper seating. 23.   Fit main and drive shafts •   Place main shaft (1) and drive shaft (4) on KM-6337 (5) •   Place end shield (3) on main shaft and drive shaft and press on with KM-6338 (2)

24.   Fit 5th gear bearing sleeve (1) •   Locate end shield on KM-6337 (3) •   Press bearing sleeve on main shaft using KM-6339 (2)

Important:   Note installation position. 25.   Fit reverse gear axle (1) •   Locate reverse idler on axle Note:   Note installation position, shift fork groove to top. •   Press reverse gear axle with inserted lock ball (arrow) to stop in end shield

26.   Attach end shield to KM-113-2 •   Attach end shield to KM-552 •   Attach end shield to KM-113-2 using KM-552 27.   Fit locking pin (1) •   Insert 3rd/4th gear and reverse gear locking pins Important:   To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin. 28.   Fit reverse gear shift fork •   Insert reverse gear shift fork (5) and shifter rod (6) •   Insert new roll pin using KM-308 (4) Note:   Allow new roll pin to protrude approximately 2 mm/0.08 in (Dimension I). Important:   To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin. 29.   Fit 1st/2nd gear shift fork •   Insert 1st/2nd gear shift fork (3) and shift rod (2) •   Insert new roll pin using KM-308 (4) Note:   Allow new roll pin to protrude approximately 2 mm/0.08 in (Dimension I).

30.   Insert 5th gear (4) shift driver. Important:   To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin. 31.   Fit 3rd/4th gear shift fork •   Insert 3rd/4th gear shift fork (2) and shift rod (1) •   Insert new roll pin using KM-308 (3) Note:   Allow roll pin to protrude approximately 2 mm. 32.   Fit locking plugs •   Fit 4x locking plugs (5, 6 and (7) Note:   Drive to stop with plastic hammer or soft metal drift. 33.   Bring gear shift fork into neutral speed position

34.   Engage 2nd, 3rd and 5th gear Note:   Turn end shield onto its side 35.   Fit bridge for lock pin •   Insert bridge for lock pins (2) in end shield, during this bring the gear shift forks into neutral position 36.   Attach bearing support (4) with pawl (3) •   Insert bearing support •   Insert 2x bolts (arrow) with locking compound •   Tighten 2x bolt - tightening torque 7 Nm

Important:   Note installation direction. Long gear hub points to end shield. 37.   Install 5th gear (driven) (2) •   Insert end shield with main and drive shafts in KM-6337 (3) •   Press on 5th gear using KM-473 (1) •   fit new retaining ring (4) Note:   Retaining ring must engage completely. 38.   Fit 5th gear (5) (driven) •   Coat needle bearings (6) with transmission fluid and place on main shaft Note:   Ensure correct seating of slotted needle bearings. •   Locate 5th gear and 5th gear synchroniser ring on main shaft

39.   Press on 5th gear synchromesh body assembly •   Insert end shield in KM-6337 •   Place synchromesh body assembly (1) on main shaft Important:   Synchroniser ring lugs must be aligned with synchromesh body grooves. •   Press synchro body in KM-473 on to main shaft •   fit new retaining ring (2) Note:   Retaining ring must engage completely. 40.   Fit bearing support with rocker arm •   Insert 2x crosshead shoes (arrow) in 5th gear shift fork (3) •   Insert bearing support with rocker arm in end shield •   Insert 2x bolts with locking compound •   Tighten 2x bolt - tightening torque 22 Nm .

41.   Install friction washer and magnet •   Fit friction washer (arrow) on axle, reverse gear wheel, with grease •   Insert magnet with grease Important:   Before installing end shield, check following items for position and seating: 1. 3rd/4th gear shift fork 2. 3rd/4th gear shift rod 3. 5th gear shift driver 4. 1st/2nd gear shift rod 5. 1st/2nd gear shift fork 6. Lock pin for gear stop 7. Reverse gear shift fork 8. Reverse gear shift rod 42.   Detach end shield from KM-113-2 •   Detach end shield from KM-552

43.   Install end shield (1) Note:   Note magnet. •   See operation "Gasket for End Shield, Replace (F13/F17/F17+/F18)". 44.   Fit end shield (2) cover •   See operation "Gasket for End Shield Cover, Replace (F13/F17/F17+/F18)". 45.   Fit gearshift cover (5) •   see operation "Gearshift Cover, Remove and Install and/or Seal (F13/F17/F17+/F18)" 46.   Transmission Fluid Level, Check and Correct •   see operation "Transmission Fluid, Check and Correct (F13/F17/F17+/F18)" 47.   Fit reversing lamp switch (3) •   insert with new seal ring •   Tighten switch for reversing lamp firmly - tightening torque 20 Nm . •   Connect wiring harness plug (4) 48.   Check gearshift •   Check ease of gear shifting with vehicle standing, engine running and clutch disengaged.