Vauxhall Workshop Service and Repair Manuals

Main Shaft, 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.   Remove main shaft

6.   Remove 1st gear gearwheel •   Push 1st gear gearwheel (4) off main shaft with KM-307-B (2) and KM-736 (1) •   Remove gear wheel and pressure piece (3) 7.   Remove 1st gear gearwheel synchro ring •   Remove needle bearing, inner synchro ring (5), intermediate ring (6) and outer synchro ring (7) 8.   Remove synchro body retainer •   Remove needle bearing •   Remove 1st/2nd gear synchro body retainer with KM-396 (8)

9.   Remove 2ndgear gearwheel •   Push 1st/2nd gear synchromesh body assembly and 2nd gear gearwheel (1) off main shaft with KM-307-B and KM-736 •   Remove 1st/2nd gear shift sleeve (2), outer synchroniser ring (3), intermediate ring (4) and inner synchroniser ring (5) from 2nd gear gearwheel (6) and needle bearing 10.   Remove pressure piece halves (arrows) •   Remove retainer (7) •   Remove pressure piece halves 11.   Remove 3rd gear gearwheel (8) 12.   Remove 3rd/4th gear synchro body retainer •   Remove 2x slotted needle bearing (9) •   Remove 3rd gear synchro ring (10) •   Remove 3rd/4th gear synchro body retainer with KM-396 (11) •   Remove spacer from synchro body

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

  Install

Important:   Coat the bearing, running or seating surfaces of rotating parts and surfaces under pressure with transmission fluid. If a synchro body assembly is completely dismantled, observe the following procedure for assembly. 17.   Assemble synchro body •   Insert synchromesh body (1) into shifter collar (2) •   Insert 3 thrust pieces (3) Note:   Attach bevel and then press into synchromesh body assembly.

18.   Fit needle bearing (1) •   Set 2 slotted needle bearings on main shaft and clip together 19.   Attach 3rd/4th gear synchro body assembly Important:   Lugs on synchro ring must be flush with grooves on synchro body •   Position 4th gear synchroniser ring (3) and synchromesh body assembly (2) on 4th gear gearwheel (4) Note:   Groove on sliding sleeve (arrow) points to 4th gear gearwheel. •   Press synchromesh body assembly (6) and 4th gear gearwheel (5) onto main shaft

20.   Attach 3rd gear gearwheel •   Place spacer on synchro body •   Fit new retainer with KM-396 (3) Note:   Retainer must be correctly seated in groove •   Place 3rd gear synchro ring (2) on synchro body assembly •   Attach 2x slotted needle bearings (1) to main shaft •   Place 3rd gear gearwheel (5) on main shaft •   Fit both thrust washer halves (arrows) and retaining ring (4) with grease 21.   Attach1st/2nd gear synchro body assembly Important:   The lugs on the synchroniser rings must align with the grooves on the synchromesh body and the gearwheel. •   Set needle bearing on main shaft •   Place 1st/2nd gear synchro body assembly (6), with inner synchro ring (9), intermediate ring (8) and outer synchro ring (7) on 2nd gear gearwheel (10) •   Push 1st/2nd gear synchro body assembly (12) and 2nd gear gearwheel (11) onto main shaft

22.   Secure 1st/2nd gear synchro body assembly (3) •   Insert new retainer (1) with KM-396 (2) Note:   Retainer must be correctly seated in groove 23.   Attach 1st gear gearwheel (5) •   Place slotted needle bearings (6) on main shaft Important:   The lugs on the synchroniser rings must align with the grooves on the synchromesh body and the gearwheel. •   Place 1st gear gearwheel with inner synchro ring (9), intermediate ring (8) and outer synchro ring (7) on 1st/2nd gear synchro body assembly (10) 24.   Attach 1st gear pressure piece (4) •   Press pressure piece to main shaft with KM-307-B (11)

27.   Install end shield (1) Note:   Observe the magnet 28.   Install end shield cover (2) 29.   Install gearshift cover (3) •   F13/F17/F17 new/F17+ •   F13 MTA/F17+ MTA 30.   Transmission Fluid Level, Check and Correct •   F13/F 17/F17 new/F17+ •   F13 MTA/F17+ MTA 31.   Install reversing lamp switch (4) •   insert with new seal ring •   Tighten reversing lamp switch 20 Nm •   Connect wiring harness plug 32.   Check ease of gear shifting •   with vehicle standing •   with engine running •   with clutch disengaged