Vauxhall Workshop Service and Repair Manuals

End Shield Dismantle and Assemble (F17+/F17+ MTA)

Note:   Transmission remains installed.

Overview of End Shield

  Remove

1.   Remove gearbox cover (1) Note:   For F17+ transmission. Remove gearshift module (2) Note:   For F17+ MTA transmission. 2.   Remove reversing lamps switch (3). •   Disconnect wiring harness plug, reversing lamp switch (4) •   Unscrew reversing lamp switch

3.   Attach KM-6001-B to front axle body •   Release 2x bolt (arrows) for adjustment rails on KM-6001-B (1) •   Insert KM-6001-B as shown Note:   2x journals (2) and (5) must sit flush in the guide holes of the front axle body. •   Tighten 2x bolt for adjustment rails •   Twist up front support bearing (4) – as far as the stop on the guide pin of the front engine damping block Note:   The guide pins must sit in the support bearings with no play. •   Twist up rear support bearing (3) – as far as the stop on the guide pin of the rear engine damping block bracket Note:   The guide pins must sit in the support bearings with no play.

5.   Remove end shield (1) cover 6.   Remove end shield (2)

7.   Attach end shield to KM-552 (2) 8.   Attach end shield to KM-113-2 (1) using KM-552

9.   Remove bearing support (1) with rocker arm (2) from end shield Note:   Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield with hot-air dryer to approximately 80 °C. •   Unscrew 2x bolt

10.   Remove 5th gear (driven) •   Detach retaining ring from synchro body (1) •   Pull gear wheel, 5th gear, and synchro body, 5th gear, away from main shaft with KM-559-A (2) •   Remove 2x needle bearing for gear wheel, 5th gear

11.   Detach gear wheel, 5th gear (driving)(2) from drive shaft (3) •   Remove retainer (1)

12.   Detach gear wheel, 5th gear, (driving) from drive shaft with KM-553-A (1) Note:   Ensure KM-553-A is correctly seated on the gear wheel, 5th gear (driving) •   Place thrust piece (2) from KM-553-A on drive shaft

13.   Detach bearing support (2) with pawl (1) from end shield •   Remove 2x bolts (arrow) Note:   Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield with hot-air dryer to approximately 80 °C.

14.   Remove locking plugs (arrows) from end shield •   Remove locking plugs with KM-727 (2) and KM-328-B (1)

15.   Detach bridge (1) for end shield locking bolt Note:   The bridge will push out if 3rd gear is then engaged •   Unscrew 2x bolt (2) Note:   Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield with hot-air dryer to approximately 80 °C. 16.   Engage 2nd gear and 5th gear •   Engage 2x gear with shift carrier (arrows)

Important:   Relieve pressure on gearshift rod guides – for this, support gearshift rods above with wood (1) 17.   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 gearshift rod (2), gearshift rod reverse gear and shift fork 18.   Remove gear shift driver •   Remove 5th gear shift driver (4) from end shield 19.   Remove locking pins (5) •   Remove roll pin for catch from end shield

Important:   Relieve pressure on gearshift rod guides – for this, support gearshift rods (1) above with wooden wedge (2) 20.   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 gearshift rod

Important:   Collect main shaft, drive shaft and reverse idler. 21.   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 gear wheel, 1st gear, is not in contact with the press. •   Collect main shaft, drive shaft and reverse idler

Important:   Note that retaining ball is released. 22.   Remove reverse gear axle (1) •   Clamp reverse gear spindle in vice Note:   Use protective jaws. •   Carefully knock off end shield with brass punch 23.   Remove bearing for main and drive shafts •   Remove 2x retaining rings (2) •   Press out 2x bearings using KM-500-5 (3)

  Install

27.   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. 28.   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)

29.   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. 30.   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

31.   Attach end shield to KM-552 32.   Attach end shield to KM-113-2 using KM-552 33.   Fit locking pin (1) •   Insert 3rd/4th gear and reverse gear locking pins Important:   To relieve pressure on gearshift rod guides in end shield, support gearshift rods with wooden wedge when securing with pin. 34.   Fit reverse gear shift fork •   Insert reverse gear shift fork (5) and gearshift 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 gearshift rod guides in end shield, support gearshift rods with wooden wedge when securing with pin. 35.   Fit 1st/2nd gear shift fork •   Insert 1st/2nd gear shift fork (3) and gearshift 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).

36.   Insert 5th gear (4) shift driver. Important:   To relieve pressure on gearshift rod guides in end shield, support gearshift rods with wooden wedge when securing with pin. 37.   Fit 3rd/4th gear shift fork •   Insert 3rd/4th gear shift fork (2) and gearshift rod (1) •   Insert new roll pin using KM-308 (3) Note:   Allow roll pin to protrude approximately 2 mm. 38.   Fit locking plugs •   Install 4x locking plugs (5...7) Note:   Drive to stop with plastic hammer or soft metal drift. 39.   Bring gear shift fork into neutral speed position

40.   Engage gear 3x •   Engage 2nd gear •   Engage 3rd gear •   Engage 5th gear 41.   Attach bridge (2) for locking bolt on end shield •   Screw in 2x new bolt Note:   Coat bolts with locking compound 42.   Move gearshift fork 1st/2nd gear into neutral 43.   Fasten 2x bolt for bridge 7 Nm 44.   Bring shift fork into neutral position. 45.   Attach bearing support (4) to end shield with pawl (3) •   Tighten 2x bolt 9 Nm Note:   Coat bolts with locking compound

Important:   Note installation direction. Long gear hub points to end shield. 46.   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. 47.   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

48.   Press on 5th gear synchro body assembly •   Insert end shield in KM-6337 •   Place synchro body assembly (1) on main shaft Important:   Synchroniser ring lugs must be aligned with synchro body grooves. •   Press synchro body in KM-473 on to main shaft •   fit new retaining ring (2) Note:   Retaining ring must engage completely. 49.   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 22 Nm

50.   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 51.   Detach end shield from KM-113-2 •   Detach end shield from KM-552

52.   Install end shield (2) 53.   Attach end shield cover (1)

56.   Fit reversing lamp switch (3) •   Tighten reversing lamp switch 20 Nm •   Connect wiring harness plug (4) to reversing lamp switch 57.   Install gearbox cover (1) Note:   For F17+ transmission. Install gearshift module (2) Note:   For F17+ MTA transmission.