Vauxhall Workshop Service and Repair Manuals

Multi-plate Clutch C3 and Freewheel F3, Dismantle and Assemble (AF22)

  Remove

2.   Attach transmission to KM-694-A (2) •   Attach assembly to KM-113-2 (1) 3.   Remove oil drain bolt (3) •   Drain transmission fluid and collect for damage diagnosis 4.   Remove converter and fluid pump seal ring

5.   Remove fluid pump assembly (1) with multi-disc brakes B1 and B2 6.   Remove freewheel F1 (2) 7.   Remove differential gear (3) 8.   Remove parking lock (4) 9.   Remove valve body (5)

10.	Remove planetary gear set P2 (1)

11.   Remove multi-plate clutch C3, freewheel F3 and brake band B4 (2)

12.   Remove flange (3), liner plates (4) and steel plates (5) from clutch body •   Prise off retainer (2) with screwdriver (1) 13.   Remove retainer (8) with KM-396 (7) •   Compress return spring assembly (10) in press using KM-698 (6) and KM-986 14.   Remove retainer (9) with return spring assembly (10) from clutch body (11)

  Install

15.   Insert clutch body (1) in primary housing (2) •   Cut off the end of KM-994 and insert KM-994 in hole Note:   Assist with pliers if necessary. •   Blow in air at low pressure (4 bar) •   Replace O-rings (3) and (5) on piston (4) 16.   Check flange (7), liner plates (8) and steel plates (6) for damage and wear, replace if necessary Note:   Place new liner plates in transmission fluid for at least 2 hours before fitting. 17.   Check return spring assembly (9) Note:   Replace if damaged.

18.   Check lock ball of piston C3 (1) •   Check by shaking whether the lock ball can move •   Check with air at low pressure (4 bar) whether the valve is sealed 19.   Measure inner diameter of front and rear clutch body bushing •   Use dial gauge MKM-571-B (2) with probe for inner diameter Note:   Carry out further measurements, form an average. Measured value: 28.5 to 28.525 mm. 20.   If worn, replace the clutch body (3) Note:   The bushings cannot be replaced individually.

21.   Check the function surfaces of the clutch body (1) for damage and wear Note:   Replace if necessary. 22.   Insert piston C3 (4) in clutch body Note:   Spring mounting faces upwards. •   Place return spring assembly (3) and retainer (2) on piston C3 23.   Attach retainer with KM-396 (7) •   Compress return spring assembly on press using KM-698 (6) and KM-986 (5)

24.   Insert flange (2) in clutch body (4) •   Insert first liner plate (3), then steel plate (1), and finally flange (5) in clutch body, alternating Note:   Rounded side faces liner plate. 25.   Press retainer (6) into groove with screwdriver 26.   Measure piston stroke of multi-plate clutch C3 Note:   If necessary, correct necessary piston stroke by installing a suitable compensating flange from the "Service" Department. •   Insert clutch body in transmission •   Place dial gauge (7) on piston C3 (8) •   Cut off the end of KM-994 and insert KM-994 in hole •   Blow in air at low pressure (4 bar) (arrow) 27.   Measured value: 1.52 to 1.89 mm

29.   Fit freewheel (1) to clutch body (2) Note:   Hold freewheel, the clutch body must be rotatable counterclockwise (I) and be locked clockwise (II). 30.   Install multi-plate clutch C3, freewheel F3 and brake band B4

31.	Install planetary gear set P2

33.   Install parking lock (3) 34.   Install differential gear (2) 35.   Install freewheel F1 (4) 36.   Install fluid pump assembly (5) with multi-disc brakes B1 and B2

Important:   Secure converter so it does not fall out
37.	Install fluid pump seal ring and converter

38.   Attach oil drain bolt (3) to transmission with seal ring Note:   Use new seal ring. •   Tighten oil drain bolt 40 Nm 39.   Detach transmission assembly with KM-694-A from KM-113-2 (1) 40.   Detach transmission from KM-694-A (2) 41.   Install transmission 42.   Top up with transmission fluid 43.   Check and correct transmission fluid level