Vauxhall Workshop Service and Repair Manuals

End Shield, Disassemble and Assemble (F17+)

Note:   Transmission remains installed.

  Remove

1.   Remove shift mechanism cover (1) •   F13/F17/F17 new/F17+ •   F13 MTA/F17+ MTA 2.   Remove reversing lamp switch (2) •   Disconnect wiring harness plug for reversing lamp switch •   Unscrew reversing lamp switch 3.   Remove end shield cover (3) 4.   Remove end shield (4)

5.   Attach end shield to KM-113-2 •   Attach end shield to KM-552 (2) •   Attach end shield with KM-552 to KM-113-2 (1) 6.   Remove bearing block (3) with pivoting lever (4) from end shield Note:   Microencapsulated bolts. If the bolts are difficult to move, heat the end shield to approx. 80°C with an industrial hot-air blower. •   Unscrew 2x bolt (6) 7.   Remove 5th gear gearwheel (driven) •   Detach retainer (5) from synchro body •   Pull 5th gear gearwheel and 5th gear synchro body from main shaft using KM-559-A (8) •   Remove both needle cages for 5th gear

8.   Remove bearing block (2) with latch (1) from end shield Note:   Microencapsulated bolts. If the bolts are difficult to move, heat the end shield to approx. 80°C with an industrial hot-air blower. •   Unscrew 2x bolt (arrow) 9.   Engage 2 gears •   Engage reverse gear and 4th gear so that transmission is immobilized 10.   Remove 5th gear gearwheel (driving) (5) •   Remove retainer(7) from drive shaft (6) •   Set KM-553-A (4) with thrust piece (3) on drive shaft and gearwheel Note:   Ensure that it is correctly seated •   Remove 5th gear gearwheel from drive shaft with KM-553-A

11.   Remove locking plugs (arrows) •   Pull plugs out of end shield with KM-727 (2) and KM-328-B (1) 12.   Remove bridge for locking bolts (3) Note:   Microencapsulated bolts. If the bolts are difficult to move, heat the end shield to approx. 80°C with an industrial hot-air blower. •   Unscrew 2x bolt (4) Note:   Turn the end shield on its side •   Engage 2nd gear and 5th gear (with shift driver) •   Engage 3rd gear and remove bridge

Important:   Relieve the gearshift rod guide by supporting the tops of the rods with a wooden wedge (1) 13.   Remove the shift forks for 3rd/4th gear and reverse •   Knock out the locating pins from the 3rd/4th gear shift lever (3) and the reverse gear lever (6), using KM-308 •   Remove shift rod (2), reverse gear shift rod and shift fork 14.   Remove gear shift driver •   Remove 5th gear shift driver (4) from end shield 15.   Remove locking bolt (5) •   Remove locking bolt from end shield

Important:   Relieve the gearshift rod guide by supporting the top of the rod (1) with a wooden wedge (2). 16.   Remove 1st/2nd gear shift fork •   Knock out the locating pin (3) from the 1st/2nd gear shift lever (4), using KM-308 •   Remove shift fork with shift rod

Warning:   Remove main shaft, drive shaft and reverse gearwheel. 17.   Dismantle main shaft and drive shaft •   Detach end shield from KM-552 •   Push main shaft and drive shaft out as shown, using KM-6335 (1) Note:   In order to press out both shafts simultaneously, apply more pressure with the press on the side of the main shaft. Make sure that the 1st gear gearwheel is not in contact with the press. •   Collect main shaft, drive shaft and reverse gearwheel

Important:   Note that retaining ball is released. 18.   Remove reverse gear wheel (1) •   Tension reverse gear wheel axle with protective jaws in a vice •   Carefully knock out end shield with brass drift 19.   Dismantle main shaft and drive shaft bearings •   Remove 2x retainer (2) •   Press out 2x bearing with KM-500-5 (3)

  Install

Important:   Coat the bearing, running or seating surfaces of rotating parts and surfaces under pressure with transmission fluid. 22.   Install the main shaft and drive shaft bearings •   Press in 2x bearing with KM-523-1 (1) and KM-6336 (2) •   Install 2x retainer (3) Note:   Ensure that the retainers are correctly seated

Important:   Ensure that the shafts are correctly seated 23.   Install the main shaft and drive shaft •   Set main shaft (1) and drive shaft (4) on KM-6337 (5) •   Set end shield (3) on main shaft and drive shaft and press on with KM-6338 (2)

24.   Install 5th gear bushing (1) •   Place end shield on KM-6337 (3) •   Push bushing with KM-6339 (2) onto main shaft

Important:   Note installation position. 25.   Install reverse gear wheel axle (1) •   Place reverse gear wheel on axle Note:   Note position, ensure that shift fork groove faces upwards •   Press the reverse gear wheel axle, with the securing ball inserted (arrow), until it comes to the stop in the end shield

26.   Attach end shield to KM-113-2 •   Attach end shield to KM-552 •   Attach end shield with KM-552 to KM-113-2 27.   Fit locking bolt (1) •   Insert locking bolts for 3rd/4th gear and reverse 28.   Install shift fork for reverse gear Important:   Support shift rods with a wooden wedge when inserting pins to relieve the gearshift rod guide. •   Insert shift fork (5) and reverse gear shift rod (6) •   Insert new locating pin with KM-308 (4) Note:   Allow pin to project approx. 2 mm (dimension I) 29.   Install 1st/2nd gear shift fork Important:   To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin. •   Insert 1st/2nd gear shift fork (3) and shift rod (2) •   Insert new locating pin with KM-308 (4) Note:   Allow pin to project approx. 2 mm (dimension I)

30.   Insert 5th gear shift driver (4) 31.   Install 3rd/4th gear shift fork Important:   To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin. •   Insert gear shift fork (2) and shift rod (1) for 3rd/4th gear •   Insert new locating pin with KM-308 (3) Note:   Allow pin to project approx. 2 mm. 32.   Install locking plugs •   Install 4x locking plugs (5, 6) and (7) Note:   Drive in as far as the stop, using a plastic hammer or soft metal drift. 33.   Move the gear shift forks to neutral position

34.   Engage 2nd, 3rd and 5th gears Note:   Turn the end shield on its side 35.   Install bridge for locking bolt •   Insert bridge for locking bolt (2) in end shield in order to move the gear shift forks to neutral position 36.   Attach bearing block (4) with latch (3) •   Install bearing block •   Insert 2x screw (arrow) with locking compound •   Tighten 2x bolts (arrow) 7 Nm

37.   Attach 5th gear gearwheel (driving) (2) Important:   Observe direction of installation. The long gearwheel hub points towards the end shield. •   Insert end shield with main shaft and drive shaft in KM-6337 (3) •   Press on 5th gear wheel with KM-473 (1) •   Fit new retainer (4) Note:   Retainer must engage fully. 38.   Attach 5th gear gearwheel (driven) (5) •   Coat needle bearings (6) with transmission fluid and place on main shaft Note:   Ensure that the slotted needle bearings are correctly seated. •   Place 5th gear gearwheel and 5th gear synchro ring on main shaft

39.   Push on 5th gear synchro body assembly •   Insert end shield in KM-6337 •   Place synchro body assembly (1) on main shaft Important:   Lugs on synchro ring must be flush with grooves on synchro body •   Push synchromesh body in KM-473 onto main shaft •   Fit new retainer (2) Note:   Retainer must engage fully. 40.   Attach bearing block with pivoting lever •   Insert 2x sliding shoe (arrow) in 5th gear shift fork (3) •   Insert bearing block with pivoting lever in end shield •   Insert 2x screw with locking compound •   Tighten 2x bolt 22 Nm

41.   Install friction washer and magnet •   Fit friction washer (arrow) on reverse gear axle with grease •   Insert magnet with grease Important:   Before installing the end shield, check the position and seating of the following: 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:   Observe the magnet 44.   Install end shield cover (2) 45.   Install gearshift cover (3) •   F13/F17/F17 new/F17+ •   F13 MTA/F17+ MTA 46.   Transmission Fluid Level, Check and Correct •   F13/F 17/F17 new/F17+ •   F13 MTA/F17+ MTA 47.   Install reversing lamp switch (4) •   insert with new seal ring •   Tighten reversing lamp switch 20 Nm •   Connect wiring harness plug 48.   Check ease of gear shifting •   with vehicle standing •   with engine running •   with clutch disengaged