Vauxhall Workshop Service and Repair Manuals

Dismantle and assemble main shaft (F23)

Note:   Transmission shafts must only be dismantled in order to replace synchronisation or bearings. The repair kits for synchro systems are obtainable from "Aftersales".

If the gearwheels are damaged the transmission must be replaced, using an exchange transmission.

  Remove

1.   Remove main shaft (1)

Important:   High compressive force is needed. Follow instruction manual for workshop press. 2.   Press 4th gear gearwheel (4) off main shaft •   Support 4th gear gearwheel with KM-6223-2 (3) and KM-6223-1 (2) •   Press main shaft out with KM-6220 (1)

3.   Press 3rd gear gearwheel (4) off main shaft (5) •   Support 3rd gear gearwheel with KM-6224 (3) and KM-6223-1 (2) •   Press main shaft out with KM-6220 (1)

4.   Remove 5th gear gearwheel (2) from main shaft (3) 5.   Remove 5th gear synchro ring (1) 6.   Detach 2 needle roller bearings (4) and (5)

7.   Remove shift sleeve (4) from synchro body Note:   Balls (1) and sliding blocks (2) are prestressed by springs (3)

8.   Push off running sleeve (3) •   Support reverse gear gearwheel (6) with KM-6221 (2) •   Press out main shaft (9) with KM-6220 (1) •   Remove running sleeve (3), 5th/reverse gear synchro body (4), reverse gear synchro ring (5), reverse gear gearwheel (6), needle-roller bearing (7) and pressure collar (8)

  Install

10.   Assemble synchronisation for 5th/reverse gear •   Place shift sleeve (2) on synchro body (1) and slide back fully •   Insert 3x sliding block (3) with spring (5) in synchro body •   Insert 3x ball (4) – Push sliding block upwards a little – With a screwdriver, press ball against spring in sliding block – Push sliding block back down in synchro body

11.   Attach pressure collar (11) to main shaft (3) 12.   Assemble reverse gear gearwheel (9) •   Attach needle-roller bearing (10) •   Slide reverse gear gearwheel carefully onto needle-roller bearing 13.   Attach reverse gear synchro ring (8) 14.   Attach 5th/reverse gear synchro body assembly (7) •   Proceed carefully so that the assembly does not come apart 15.   Attach 5th gear synchro ring (6) 16.   Attach 5th gear gearwheel (4) •   Push on running sleeve for needle-roller bearing (5) •   Attach 2x needle roller bearing •   Slide 5th gear gearwheel carefully onto needle-roller bearing 17.   Attach 3rd gear gearwheel (2) •   Push onto main shaft with KM-514 (1)

18.   Attach 4th gear gearwheel (2) •   Push onto main shaft (3) with KM-6219 (1)