Vauxhall Workshop Service and Repair Manuals

Main Shaft, Dismantle and Assemble (F17+/F17+ MTA)

Overview of Drive Shaft

Note:   Transmission remains installed.

  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 Note:   The guide pins must sit in the support bearing with no play. •   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) – until the guide pin is in contact with the front of the engine damping block •   Twist up rear support bearing (3) – until the guide pin is in contact with the rear of the engine damping block

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

7.   Detach 1st gear (4). •   Press 1st gear off main shaft with KM-307-B (2) and KM-736 (1). •   Remove gear wheel, 1st gear, and thrust washer (3) 8.   Detach 3x synchroniser ring, gear wheel, 1st gear •   Remove needle bearing, inner synchroniser ring (5), intermediate ring (6) and outer synchroniser ring (7) 9.   Remove synchro body retaining ring •   Remove needle bearing •   Remove retaining ring synchro body 1st/2nd gear using KM-396 (8)

10.   Detach 2nd gear •   Press synchro body assembly 1st/2nd gear and gear wheel for 2nd gear (1) off main shaft with KM-307-B and KM-736 •   Remove shift sleeve 1st/2nd gear (2), outer synchro ring (3). intermediate ring (4) and inner synchro ring (5) from gear wheel of 2nd gear (6) and needle bearing 11.   Detach thrust washer halves (arrows) •   Remove retaining ring (7) •   Detach thrust washer halves 12.   Remove 3rd gear gearwheel (8) 13.   Remove retaining ring synchro body 3rd/4th gear •   Remove 2x slotted needle bearings (9) •   Remove 3rd gear (10) synchroniser ring •   Remove retaining ring synchro body 3rd/4th gear using KM-396 (11) •   Remove spacing ring from synchro body

14.   Detach 4th gear •   Press off gear wheel, 4th gear (4), and synchro body with KM-307-B •   Remove synchro body 3rd/4th gear assembly (2), synchro ring 4th gear (3) from 4th gear 15.   Detach needle bearing (5) •   Remove 2x slotted needle bearings from main shaft Note:   Open needle bearing

  Install

Important:   Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid. If a synchro body assembly has been completely disassembled then the following method of procedure shall be observed for assembly. 18.   Assemble synchro body •   Insert synchro body (1) into shift sleeve (2). •   Insert 3x thrust piece (3) Note:   Position at an angle and then press into the synchro body assembly.

19.   Fit needle bearing (1) •   Place 2x slotted needle bearing on main shaft and clip together Important:   Synchroniser ring lugs must be aligned with synchro body grooves. 20.   Attach synchro body assembly 3rd/4th gear •   Position 4th gear synchro ring (3) and synchro body assembly (2) on 4th gear (4). Note:   Groove on slider sleeve (arrow) points to 4th gear. •   Press synchro body assembly (6) and 4th gear (5) on to main shaft

21.   Fit 3rd gear •   Locate spacing ring on synchro body •   Attach retaining ring with KM-396 (3) Note:   Use new retaining ring. Retaining ring must sit in groove correctly. •   Locate synchroniser ring 3rd gear (2) on synchro body assembly •   Attach 2x slotted needle bearings (1) to main shaft. •   Locate 3rd gear (5) on main shaft •   Fit both halves of the thrust washer (arrows) and retaining ring (4) using grease Important:   Lugs of the synchro rings must be flush with the grooves of the synchro body and the gear wheel. 22.   Attach synchro body assembly 1st/2nd gear •   Place needle bearing on main shaft •   Locate synchro body 1st/2nd gear (6) with inner synchro ring (9), intermediate ring (8) and outer synchro ring (7) on gear wheel for 2nd gear (10) •   Press synchro body assembly 1st/2nd gear (12) on to main shaft with 2nd gear (11)

23.   Secure synchro body assembly 1st/2nd gear (3) •   Insert new retaining ring (1) using KM-396 (2) Note:   Retaining ring must sit in groove correctly. 24.   Attach 1st gear (5) •   Locate slotted needle bearing (6) on main shaft Important:   Lugs of the synchro rings must be flush with the grooves of the synchro body and the gear wheel. •   Locate 1st gear with inner synchro ring (9), intermediate ring (8) and outer synchro ring (7) on synchro body assembly 1st/2nd gear (10) 25.   Fit thrust washer 1st gear (4) •   Press thrust washer onto main shaft (11) using KM-307-B

28.   Install end shield (2) 29.   Attach end shield cover (1)

32.   Fit reversing lamp switch (3) •   Tighten reversing lamp switch 20 Nm •   Connect wiring harness plug (4) to reversing lamp switch 33.   Install gearbox cover (1) Note:   For F17+ transmission. Install gearshift module (2) Note:   For F17+ MTA transmission.