Vauxhall Workshop Service and Repair Manuals

Main shaft, dismantle and assemble (F13/F13 MTA)

Note:   Transmission remains installed.

  Remove

1.   Remove gearshift cover (1) •   F13/F17/F17 new/F17+ •   MTA 2.   Remove reversing lamp switch (2) •   F13 only 3.   Remove end shield cover (3) gasket 4.   Remove end shield (4) from transmission

5.   Remove main shaft Note:   If the gears are damaged, always also replace the gear cluster. 6.   Push off ball bearing (3), spacer washer (4), retaining ring (6), axial needle bearing (5) and 1st gear gearwheel (7) with KM-307-B (2) •   Use suitable drift (1) 7.   Remove needle bearing (8) for 1st gear gearwheel from main shaft 8.   Remove inner synchro ring (9), intermediate ring (10) and outer synchro ring (11) for 1st gear gearwheel from synchroh body assembly (12)

9.   Remove retaining ring for 1st/2nd gear synchro body assembly (1) with circlip pliers (2) 10.   Remove shift sleeve (7), synchro spring (6) and sliding blocks (3 and 5) from synchro body (4) 11.   Push synchro body (8), inner synchro ring (9), intermediate ring (10) and outer synchro ring (11) for 2nd gear gearwheel (12) from main shaft with KM-307-B (14) •   Use suitable drift (13)

12.   Remove retaining ring (1) in front of drive gear (driving) from main shaft 13.   Push drive gear (driving) (3) from main shaft with KM-307-B (4) Note:   Always replace drive gears (driving and driven) in pairs •   Use suitable drift (2)

14.   Place KM-307-B (1) in groove of 4th gear gearwheel (2) 15.   Push 4th gear gearwheel and spacer washer (4) from main shaft with KM-307-B •   Use suitable drift (3) 16.   Remove needle bearing (5) (if present), synchro ring (4th gear gearwheel) (6), shift sleeve (7), synchro spring and sliding blocks from main shaft 17.   Push 3rd/4th gear synchro body (9), synchro ring and 3rd gear gearwheel (10) from main shaft with KM-307-B •   Use suitable drift (8)

  Install

18.   Clean all parts 19.   Immerse all parts in transmission fluid before installation. 20.   Check all removed parts for damage and wear, replace if necessary 21.   Lubricate all bearing bore holes and seating surfaces with transmission fluid before installation. 22.   Transmission has 3 cone synchronisation for 1st/2nd gear: 1. 2nd speed gear 2. Inner synchroniser rings 3. Intermediate rings 4. Outer synchroniser rings 5. Shift sleeve 6. Synchroniser springs 7. Sliders 8. Synchromesh body 9. 1st speed gear

23.   Insert synchro body (3) in shift sleeve (2) Note:   Synchromesh body assembly 1st/2nd gear and 3rd/4th gear can only be pressed onto main shaft in assembled state. 24.   Insert sliding blocks (1) and (5) •   with the open side towards the synchro body 25.   Insert synchroniser spring (4) Note:   Ensure that the free end is raised from the synchro body (arrow) in the correct installation position. If this is not the case, turn synchro ring by 180° and re-install. •   Offset end of synchro spring engages in a sliding block

26.   Attach needle bearing (2) for gear wheel, 3rd gear, to main shaft (1) Note:   If present. 27.   Push 3rd gear gearwheel (3) onto main shaft from drive wheel side •   Cone (arrow) points in direction of drive wheel 28.   Place synchroniser ring (4) onto 3rd gear cone. 29.   Press synchro body assembly for 3rd/4th gear (6) with KM-277 (5) onto main shaft.

30.   Attach needle bearing, gear wheel, 4th gear to main shaft Note:   If present. 31.   Attach synchro ring (3) and 4th gear gearwheel (2) to main shaft 32.   Place spacer washer (1) onto drive shaft •   Four grooves (arrows) must point towards 4th gear gearwheel 33.   Press drive wheel (5) onto main shaft with KM-311-2 (4) Note:   Always replace drive gears in pairs. •   Shoulder must point towards spacer washer 34.   Fit new retaining ring (6) in front of drive gear

35.   Slide 2nd gear gearwheel (4) onto main shaft 36.   Place inner synchro ring (3) onto cone of gearwheel •   Lugs must sit in grooves of gear wheel 37.   Place intermediate ring (2) onto inner synchro ring 38.   Place outer synchro ring (1) onto intermediate ring •   Grooves must sit on lugs of inner synchro ring 39.   Place synchro body assembly (5) onto main shaft 40.   Press synchro body assembly onto main shaft with KM-277 (6) •   Lugs in outer synchro ring must align with grooves in synchro body •   Shift fork groove (arrow) points towards ball bearing seat 41.   Insert new retaining ring (8) in front of 1st/2nd gear synchro body with circlip pliers (7)

42.   Place outer synchro ring (3) with lugs in grooves of synchro body (4) 43.   Place intermediate ring (2) onto outer synchro ring 44.   Place inner synchro ring (1) onto intermediate ring •   Lugs must engage in grooves of outer synchro ring 45.   Place 1st gear needle bearing (5) onto main shaft Note:   If present. 46.   Slide 1st gear gearwheel onto needle bearing •   Grooves must sit on lugs of intermediate ring 47.   Place axial needle bearing (8) onto 1st gear gearwheel (10) •   Place spacer washer (7) onto needle bearing 48.   Place new retaining ring (9) with long legs for main shaft at end shield onto 1st gear gearwheel •   Press ball bearing (6) onto main shaft with KM-334 (11)

49.   All gears must turn easily 50.   Install main shaft 51.   Install end shield (1) in transmission 52.   Install end shield cover (2) 53.   Install reversing lamp switch (4) with new seal ring •   F13 only •   Tighten switch 20 Nm 54.   Install gearshift cover (3) •   F13/F17/F17 new/F17+ •   MTA