Vauxhall Workshop Service and Repair Manuals

Seal complete transmission (F23)

Note:   This operation requires the transmission to be dismantled. The components must be inspected for any damage due to inadequate lubrication and replaced if necessary.

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

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

Important:   The use of pulse screwdrivers or impact screwdrivers to remove bolts from transmission shafts is not permitted.

  Remove

2.   Attach transmission (2) to workbench with KM-113-2 (4) and KM-6115 (1) and (3) •   Attach transmission to KM-6115 with 4x bolt (arrows) •   Attach transmission with KM-6115 to KM-113-2

3.   Remove pressure line (1) •   Remove pressure line from central release (2) – Unscrew bolt •   Disengage 2x retaining lug (4) – Carefully lever outwards with screwdriver •   Remove pressure line 4.   Remove pressure line sleeve (3) •   Release and remove from clutch housing

5.   Remove central release (1) •   Remove 3x bolts 6.   Remove intermediate shaft cover (3) •   Knock out with KM-328-B (4) and KM-6101 (5) – Using a suitable drift (2) drive in hole centrally (6) – Screw KM-6101 flush into the cover 7.   Remove transmission fluid pipe

8.   Engage 3rd or 4th gear •   at gear shift assembly 9.   Unscrew intermediate shaft connection (3) •   Lock drive shaft (2) with KM-6117 (1) •   Then remove KM-6117 10.   Tilt transmission in KM-113-2 90° to the left

11.   Remove transmission housing cover (1) •   Unscrew 8x bolt Important:   Do not damage sealing surface •   Release and remove transmission housing cover using KM-J-37228 (2) 12.   Remove transmission fluid collector pipe (3)

13.   Unscrew main shaft (2) and drive shaft (3) connection •   Lock drive shaft with KM-6117 (1) •   Then remove KM-6117 14.   Put transmission into neutral •   at gear shift assembly

15.   Dismantle gear shift assembly (1) •   Unscrew fit bolt (3) •   Unscrew 5x bolt (arrows) •   Remove gear shift assembly 16.   Remove reversing lamp switch (2) •   Detach reversing lamp switch wiring harness plug •   Unscrew reversing lamp switch

17.   Release transmission housing (2) from clutch housing (1) •   Remove 12x bolt (arrows) from clutch housing (1) •   Tilt transmission in KM-113-2 90° to the left •   Remove 7x bolt (arrows) from transmission housing (2)

18.   Release transmission housing from clutch housing •   Attach KM-6116 (2) – with 4x bolt (3) on transmission housing – Screw 2x spindle at least 5 revolutions into main shaft and drive shaft •   Pull transmission housing and both bearings from clutch housing, main shaft and drive shaft using KM-6116 Note:   Turn both nuts (4) evenly to pull transmission housing off. Tighten nuts alternately by 90° approx., counterholding at hex head (1) •   Detach KM-6116 •   Remove transmission housing

19.	If necessary: assemble 3rd/4th gear synchro body

20.   Remove magnet (5) from transmission housing and clean it. 21.   Secure 3rd/4th gear synchro body assembly against falling apart, Note:   making sure that the drive shaft friction washer (3) is not left behind in the transmission housing. •   Attach KM-6121 (2) to drive shaft (4) – Screw in bolt (1)

22.   Remove gear shift shaft (1) from transmission housing •   Remove gear shift shaft guide sleeve (2) – Press out of transmission housing from inside and remove •   Remove gear shift shaft 23.   Remove transmission fluid pipe from transmission housing

24.   Dismantle main shaft (3), intermediate shaft (1) and drive shaft (2) with shift forks Note:   A second fitter is needed to hold the main shaft, intermediate shaft and drive shaft with shift forks still and remove them. •   Knock intermediate shaft out with KM-6126 and KM-523-1 – out of bearing in clutch housing

25.   Remove differential gear(1) from clutch housing 26.   Remove main shaft roller bearing (2) from clutch housing

27.   Remove main shaft bearing from transmission housing •   Knock out with KM-6122 (1) and KM-523-1 (2) 28.   Remove drive shaft bearing from transmission housing •   Knock out with KM-6123 (3) and KM-523-1 (4)

29.   Remove 2x axle shaft seal from clutch housing and transmission housing •   using MKM-557-1 (1) and MKM-557-2 (2)

  Install

32.   Install 2x axle shaft seal in clutch housing and transmission housing •   using KM-519 (1)

33.   Insert main shaft roller bearing •   Shoulder (arrows) faces the clutch housing 34.   Insert main shaft (4), intermediate shaft (1) and drive shaft (3) with shift forks in clutch housing Note:   A second fitter is needed. •   Drive the intermediate shaft (arrow) into the bearing in the clutch housing Important:   To prevent damage to components when driving the intermediate shaft into the bearing, continuously monitor the installation position with respect to the seating of the shafts and shift forks in the clutch housing. – Use a plastic hammer Important:   Do not move the shift sleeve. 35.   Remove KM-6121 (2)

Important:   Do not remove retaining rings (arrows) from bearings. Retaining rings cannot be fitted if bearing is installed. Replace main shaft bearing 37.   Place bearings for drive shaft (1) and main shaft (2) on transmission housing (3)

38.   Attach KM-6116 (1) with 2x pressure pad KM-6116-3 (3) •   Place 2x KM-6116-3 on spindle •   Install KM-6116 with 4x bolt (arrow) on transmission housing (2) •   Screw 2x spindle into main shaft and drive shaft – approx. 5 revolutions

39.   Pull bearings of main shaft and drive shaft into transmission housing and onto both shafts Note:   This step pulls the bearing and the transmission housing onto the shafts and puts the transmission housing on the clutch housing. Important:   Do not use any force. If considerable force is needed when operating KM-6116 , separate the transmission housing from the clutch housing and check the positions of the shafts and shift forks, then repeat the step. Make sure that the transmission housing is correctly positioned above the clutch housing. •   Counterhold each of the 2 spindles at the head (1) •   Turn 2x nut (2) in direction of arrow Note:   Pull the bearings evenly onto the main shaft and drive shaft by tightening nuts (2) of KM-6116 alternately until a pressure point is reached. •   Remove KM-6116 from transmission •   If necessary: drive bearings for main shaft and drive shaft into transmission housing – until they are against the retainers on the transmission housing – Use KM-6116-3 and a plastic hammer 40.   Screw 2 bolts into main shaft and drive shaft •   Use old bolts •   Do not tighten them Note:   The main purpose of the two old screws in the main shaft and the drive shaft is to provide temporary assistance during installation

41.   Detach transmission housing with main shaft, intermediate shaft, drive shaft and shift forks from the clutch housing (1) •   Secure the transmission housing to the clutch housing – Screw 4x bolt •   Rotate transmission 180° with KM-6115 in KM-113-2 •   Unscrew 4x bolt Note:   A second fitter is needed to hold the transmission housing steady. •   Drive intermediate shaft out of clutch housing – using KM-6126 and KM-523-1 (2) •   Place transmission housing on workbench and support it – with a suitable piece of wood

42.   Insert transmission fluid pipe (5) 43.   Install gear shift lever (4) •   Ensure that it engages in the shift forks 44.   Install gear shift shaft guide sleeve (3) 45.   Insert magnet in transmission housing 46.   Install gear shift assembly (2) •   Apply sealing compound – to gear shift assembly sealing surface •   Insert gear shift assembly – Ensure that it engages in the shift forks •   Tighten 5x bolt 25 Nm 47.   Install differential gear (1) in transmission housing

48.   Install fit bolt (1) of gearshift assembly 25 Nm •   Apply screw locking compound to thread (arrow) •   Fit bolt must engage in gear shift assembly 49.   Attach clutch housing to transmission housing •   Check seating of main shaft roller bearing (3) – Shoulder (arrows) faces upwards •   Apply sealing compound to sealing surface of transmission housing (2) – Max. width 2 mm – Spread sealing compound •   Remove clutch housing with KM-6115 from KM-113-2 •   Set clutch housing with KM-6115 on transmission housing Note:   The main shaft and drive shaft in their bearings must engage in the clutch housing. Shift forks must be seated in their bearings in the clutch housing.

50.   Pull the intermediate shaft, in its bearing, into the clutch housing (1) •   Screw in old bolt (2) 51.   Fit 12x screw (arrows) •   Tighten evenly in crosswise formation 28 Nm

52.   Attach transmission with KM-6115 to KM-113-2 53.   Fit 7x screw (arrows) •   Tighten bolts evenly in crosswise formation 28 Nm 54.   Fit 3 new bolts in main shaft, intermediate shaft and drive shaft 100 Nm •   Engage gear – and check gear shifting •   Lock drive shaft with KM-6117 •   Unscrew 3 old bolts (2) and (3) •   Insert 3x new bolts with locking compound •   Remove KM-6117

55.   Insert fluid collector pipe 56.   Install transmission housing cover •   Apply a thin coat of sealing compound evenly to sealing surface Important:   Do not apply any sealing compound in area (1) so as not to block transmission fluid pipe (2) •   Tighten 8x bolt 25 Nm

57.   Insert transmission fluid pipe (5) in intermediate shaft 58.   Drive intermediate shaft cover (4) in flush into clutch housing •   using KM-6102 ) and KM-523-1 (3) 59.   Install new central release (7) •   Slide central release onto drive shaft with KM-6059 (6) •   Tighten 3 bolts 5 Nm •   Remove KM-6059 60.   Install pressure line (2) •   Insert pressure line sleeve (1) into clutch housing •   Insert pressure line into pressure line sleeve – Pressure line must engage in sleeve •   Attach pressure line to central release – Tighten union bolt 14 Nm

Important:   A damaged or faulty O-ring (1) leads to leaks at the hydraulic clutch actuation 61.   Check that the O-ring is not damaged and is correctly seated 62.   Install reversing lamp switch (2) 20 Nm •   Insert with (green) sealing compound

63.   Detach transmission (4) from KM-6115 (1) and (3) •   Remove clutch housing with KM-6115 from KM-113-2 (2) •   Unscrew 4x bolt 64.   Install transmission