Vauxhall Workshop Service and Repair Manuals

Illustration – Assemblies

Removing transmission - see operation "Removing and installing manual transmission (vehicles with 4-cylinder petrol engine)", "Removing and installing manual transmission (X 20 DTH, Y 22 DTH)", "Removing and installing manual transmission (25 DT, X 25 DT)", "Removing and installing manual transmission (Y 25 DT) or "Removing and installing manual transmission (vehicles with V6 engine)".

  Install

KM-622 to transmission nose piece, transmission to KM-113-2.

  Remove

Remove retaining plate (arrow) for vent line – commercially available pliers.

Unscrew pressure line (2) from central release.

Loosen vent line (1) at central release.

Release central release from transmission, 3 bolts (3).

Remove entire central release with vent line (1). Unscrew vent line from central release.

Pull pressure line (2) out of transmission housing with rubber sleeve.

Fluid filler plug (1) from right transmission side, fluid drain plug (2) from transmission nose piece.

Drain transmission fluid.

Connecting piece with shift rod from shift lever shaft.

Fold folding cover forwards (arrow), detach retaining clip (1), drive out pin with suitable drift and hammer.

Caution

Outer shift rod (2) remains attached.

Unbolt reversing lamp switch (1) from transmission. Note spacer ring.

Knock 1 closure plug (1) for locking bolt out of transmission housing, KM-630-1 (1) and KM-328-B (2) (right transmission side).

Remove locking bolt with pressure spring from front section of transmission housing.

Remove retaining ring from bearing of main drive gear.

Output shaft flange from transmission, counterhold with KM-623 and unscrew using hex socket (size 30, extra long).

Turn transmission vertically downwards. Install KM-628-A with 3 screws to output shaft flange (arrows).

Screw KM-628-A in flush – counterhold at hex and remove output shaft flange.

Turn transmission to horizontal position.

Unscrew fastening bolt for reverse idler gear shaft.

10 fastening bolts for transmission nose piece (arrows).

  Install

Fasten KM-628-A (1) to transmission housing with central release fastening bolts.

  Remove

Remove transmission housing from transmission nose piece using KM-628-A, bearing for main drive gear remains in housing.

Cover for stop balls from transmission.

Caution

Cover under spring pressure.

  Remove

Pressure springs from transmission.

3 stop balls from transmission using bar magnet.

Grooved pins for shift forks using drift.

Pull shift rods out of shift forks, remove shift rods from transmission nose piece.

If necessary, twist shift shaft (1) so that shift finger does not handicap removal of shift rods.

Fastening screw for reverse idler shaft (1) from transmission nose piece, pull out reverse idler shaft slightly and remove with reverse gear in direction of arrow.

Compress retaining ring for main shaft bearing with KM-627. Hold retaining ring tensioned – apply KM-627-1-A from above.

Heat transmission nose piece in area of main shaft bearing seat to approx. 100 °C/212 °F using industrial hot air blower.

Check temperature with thermocolour pencils or suitable temperature gauge.

Remove main shaft and auxiliary shaft gear cluster from transmission nose piece.

Install main drive gear (1) with synchroniser ring (2) and bearing cage (3) onto main shaft.

Assemble auxiliary shaft gear cluster and main shaft.

Assembled main shaft with auxiliary shaft gear cluster in transmission nose piece.

Heat transmission housing nose piece in area of bearing seat to approx. 100 °C/212 °F, industrial hot air blower, thermocolour pencils or suitable temperature gauge.

Caution

Position of retaining ring. Do not jam retaining ring at transmission nose piece. Insert KM-627-1 (1) opposite rocker on retaining ring.

Remove KM-627-1 (2) from retaining ring (3) – remove tensioner, adjust with retaining ring pliers (1) so that retaining ring engages in groove.

  Install

Drive new seal ring for output shaft flange into transmission nose piece with KM-629-1 (4).

Drive shaft flange onto teeth of main shaft, insert new fastening nut with locking compound.

Counterhold drive shaft flange with KM-623 – hexagon wrench (A/F 30, extra long) – 150 Nm / 111 lbf. ft.

Install double-row needle roller bearing (1) in reverse idler gear (2). Insert reverse idler gear in transmission. Identification groove (arrow) points to driving direction.

Push reverse idler gear shaft (1) through until rear screw (2) can be inserted into nose piece.

Torque

Reverse idler gear shaft to transmission – 22 Nm / 16 lbf. ft.

Coat 2 locking pins for gearshift rods with lubricating grease and insert with bar magnet into transmission nose piece.

All shift forks onto respective sliding sleeve:

5th/reverse shift fork (1): Recognisable by offset, the rounded heel (arrow) points to the drive side.

1st/2nd shift fork (2): Lubricating duct (3) points to the drive side.

3rd/4th shift fork (4): Shift fork has no offset, the rounded heel (arrow) points to the output side.

Push 1st/2nd shift rod with shift driver through shift fork and place in transmission nose piece. Align bore holes for grooved pin.

Caution

All sliding sleeves are in idle position.

Install 3rd/4th shift rod in shift fork, so that recesses point away from 1st/2nd shift rod. Insert 3rd/4th shift rod in centre bore hole in transmission nose piece, so that bore holes for grooved pins align.

Place 4 rollers on shift lever shaft and adhere by inserting with lubricating grease.

Install shift lever shaft with shift finger into selector rocker in transmission nose piece.

Position of shift finger, turn selector rocker slightly if necessary.

5th/reverse shift rod into shift fork and transmission nose piece, so that bore holes for grooved pin are aligned.

Drive 3 grooved pins (1, 2, 3) into shift forks and shift rods using KM-308.

Caution

Support shift rod ends (e.g. using wooden block). Drive in grooved pins, so that they protrude approx. 1 mm/0.04 in.

Insert 3 locking balls and 3 pressure springs into transmission nose piece.

Torque

Cover – install with sealing compound at transmission nose piece (2 bolts) – 10 Nm / 7.5 lbf. ft.

  Install

Closure plugs (arrow) for locking pins at transmission nose piece – drive in fluid-tight with plastic hammer.

Drive in seal ring for shift lever shaft flush with KM-629-3 (1). Turn transmission to vertical position. Engage 4th gear.

Caution

All synchroniser rings must be loosely seated. Loosen firmly seated synchroniser rings from cone of gear.

Apply sealing compound to sealing surface of transmission nose piece.

Front section of transmission housing to transmission nose piece. Ensure that shift rods are inserted correctly into bore holes in transmission.

Ball bearing with retaining ring to main drive gear.

Place bushing KM-461-3 (1) on drive shaft, lubricate moving parts of Tool KM-461-C. Screw holder rod into KM-461-C to stop. Slide KM-461-C with holder rod over bushing KM-461-3 and tighten bolts (2).

Length (2) of holder rod (1) can be varied by screwing into or out of the thread.

Unscrew holder rod (1) from KM-461-C until end of holder rod lies on a reinforcement rib (arrow).

Heat transmission housing in bearing seat area to approx. 100 °C. Use industrial hot air blower and thermocolour pencils or suitable temperature gauge.

Press ball bearing flush to retaining ring in front section of transmission housing using KM-461-C (3) by turning on square drive shaft (1/2").

Retaining ring to main drive gear, retaining ring pliers.

Put transmission into idle position.

  Inspect

Ensure that output flange can be turned in all transmission gears.

Install 10 screws (arrows) of transmission nose piece – 22 Nm / 16 lbf. ft.

Front screw (arrow) of reverse idler gear shaft – 22 Nm / 16 lbf. ft.

Pre-install vent line (1) to central release.

Torque

Central release to transmission (3 screws, 3) – 22 Nm / 16 lbf. ft.

Attach pressure line (2) with grommet and bolt to central release – 14 Nm / 10 lbf. ft.

  Install

Retaining plate (arrow) for vent line.

Pressure spring (white marking) and pin (with roller in horizontal position) into transmission.

Drive in cover using plastic mallet. For widened bore hole, an oversized cap is available.

Switch for reversing lamps with spacer (1) – 20 Nm / 15 lbf. ft.

Install connecting piece (2) with outer shift rod, install pin and retaining clamp (1). Folding cover.

Torque

Fluid drain bolt (2 in illus. E 7517) – 30 Nm / 22 lbf. ft.

Top up transmission fluid up to 9 mm beneath the fluid filler bore hole (1) – approx. 1.2 litres – see also operation "Fluid Level, Check and Correct". Fluid quality – see "Technical Data".

Torque

Fluid filler plug – 30 Nm / 22 lbf. ft.

Remove transmission from KM-113-2 and KM-622.