repair instructions - off vehicle

8/12/2019 Repair Instructions - Off Vehicle

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1. Attach transmission to KM-6115 (2).

2. Attach transmission to KM-113-2 (1) using KM-6115.

3. Remove left engine damping block bracket.

Remove 3x bolts.

4. Put transmission into neutral.

I mportant: Shift transmission to neutral position.

5. F17+ MTA: Remove gearshift module. Refer to Transmission Control Replacement.

F17+: Complete the following procedure:

Page 2 of 23Document ID: 2004044

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Unscrew 4x bolt.

5.1. Press adjusting pin (2) into adjusting bore.

I mportant: The adjusting pin is at the front in the direction of travel.

5.1. Turn gearshift rod anti-clockwise (in direction of 3rd gear).

I mportant: Cover aperture in transmission.

5.2. Detach gearbox cover (1) from transmission.




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5.3. Clean sealing surfaces, remove sealant residues.

5.4. Measure clearance (I) between alignment pin (2) and actuating mechanism (1) of the

gearshift rod 3rd/4th gear.

Measure with feeler gauge

Clearance must be approx. 0.5 mm (0.0197 in)

-

If clearance is too great, drive alignment pin further into the transmission housing

with a drift punch and measure clearance again.

-

If clearance is too small: No correction of clearance necessary because the gearshift

rod presses the alignment pin into the correct position.




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Turn gearshift rod (2) with gearshift finger in the direction of the arrow.

5.9.1. Remove bush (6)

5.9.2. Remove compression spring (7)

5.9.3. Remove washer (8)

5.10. Detach gearbox cover from KM-982.

5.11. Remove intermediate gearshift lever (1).

5.12. Remove gearshift rod from gearbox cover.




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Knock roll pin out of gearshift finger (3) with drift punch. Note recess in cover.

6. Unscrew reversing lamp switch (1).

I mportant: Place collecting pan underneath - transmission fluid will escape

7. Remove end shield cover.

I mportant: Do not further dismantle gearbox cover.

5.13. Prise seal ring (4) out of gearbox cover.




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Unscrew 9x bolt. If necessary, release the end shield cover by striking it gently with a rubber

mallet.

Detach end shield cover gasket.

I mportant: When dismantling the end shield it is essential to use KM-6155 (2) as otherwise

the shaft seal ring of the central release will be damaged.

I mportant: Be careful of guide sleeves, magnet (3) and spacer washer (4) for axle reverse

idler gear.

8. Screw KM-6155into threaded bores.

9. Detach end shield.

Unscrew 4x bolt (arrows).

10. Check all parts for damage. Replace damaged components.11. Clean sealing surfaces.12. Detach KM-6155.




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13. Attach end shield to KM-552 (2).

14. Attach end shield to KM-113-2 (1) using KM-552.




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I mportant: Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield

with hot-air dryer to approximately 80C (176F).

15. Remove bearing support (1) with rocker arm (2) from end shield.

Unscrew 2x bolt.

16. Remove 5th gear (driven).

Detach retaining ring from synchro body (1)

Pull gear wheel, 5th gear, and synchro body, 5th gear, away from main shaft with KM-

559-A (2)

Remove 2x needle bearing for gear wheel, 5th gear




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17. Detach gear wheel, 5th gear (driving) (2) from drive shaft (3). Remove retainer (1).




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I mportant: Ensure KM-553-Ais correctly seated on the gear wheel, 5th gear (driving).

18. Detach gear wheel, 5th gear, (driving) from drive shaft with KM-553-A (1).

Place thrust piece (2) from KM-553-Aon drive shaft.




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I mportant: Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shieldwith hot-air dryer to approximately 80C (176F).

19. Detach bearing support (2) with pawl (1) from end shield.

Remove 2x bolts (arrow).

20. Remove locking plugs (arrows) from end shield.




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Remove locking plugs with KM-727 (2) and KM-328-B (1).

21. Detach bridge (1) for end shield locking bolt. The bridge will push out if 3rd gear is then

engaged.

I mportant: Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shieldwith hot-air dryer to approximately 80C (176F).

22. Unscrew 2x bolt (2).

23. Engage 2nd gear and 5th gear.

Engage 2x gear with shift carrier (arrows).




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I mportant: Relieve pressure on gearshift rod guides - for this, support gearshift rods (1)

above with wooden wedge (2).

27. Remove 1st/2nd gear shift fork.

Drive roll pin (3) out of 1st/2nd gear shift fork (4) using KM-308

Take out shift fork with gearshift rod




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I mportant: Note that retaining ball is released.

29. Remove reverse gear axle (1).

30. Remove bearing for main and drive shafts.

31. Clean all parts and sealing surfaces.

32. Check all parts. Replace damaged components.

I mportant: Use protective jaws

Clamp reverse gear spindle in vice

Carefully knock off end shield with brass punch

Remove 2x retaining rings (2)

Press out 2x bearings using KM-500-A-5 (3)




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I mportant: Place collecting pan underneath - transmission fluid will escape

33. Detach differential cover (1).

Unscrew 10x bolt.

34. Mark position of bearing race (2) in respect of transmission (arrow).




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35. Remove bearing race with KM-447 (2).

Remove retaining plate (1) from bearing race - unscrew bolt.

36. Remove differential downwards.

37. Detach pressure line (1). Unscrew union nut.

38. Remove central release. Remove 3x bolt (arrow).




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39. Check seal ring (1) on central release for damage. Replace damaged components.




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42. Remove needle bearing (3) for drive shaft.

Remove needle bearing from transmission housing with KM-556-A (1) and MKM-559 (2).

43. Remove roller bearing (4) for main shaft.

Remove roller bearing from transmission housing with KM-556-A (6) and KM-556-A-2 (5).

44. Remove 2x axle shaft seal ring with KM-557-A-1 (2) and KM-557-A-2 (1) from transmission

housing.

45. Remove transmission housing from KM-6115.




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2008 Saturn Astra| Astra (VIN A) Service Manual| Transmission/Transaxle| Manual Transmission - F17-5|

Repair Instructions - Off Vehicle| Document I D: 2004045

Output Shaft Disassemble

Special Tools

Main Shaft, Dismantle ( F17+/ F17+ MTA)

1. Detach 1st gear (4).

2. Detach 3x synchronizer ring, gear wheel, 1st gear.

KM-307-BRemover Plate

KM-396Ring Pliers

KM-736Guide Bolt

Press 1st gear off main shaft with KM-307-B (2) and KM-736 (1)

Remove gear wheel, 1st gear, and thrust washer (3)

2010 General Motors Corporation. All rights reserved.




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Remove needle bearing, inner synchronizer ring (5), intermediate ring (6) and outer

synchronizer ring (7).

3. Remove synchro body retaining ring.

4. Detach 2nd gear.

5. Detach thrust washer halves (arrows).

6. Remove 3rd gear gearwheel (8).

7. Remove retaining ring synchro body 3rd/4th gear.

Remove needle bearing

Remove retaining ring synchro body 1st/2nd gear using KM-396 (8)

Press synchro body assembly 1st/2nd gear and gear wheel for 2nd gear (1) off main shaft

with KM-307-Band KM-736

Remove shift sleeve 1st/2nd gear (2), outer synchro ring (3), intermediate ring (4) andinner synchro ring (5) from gear wheel (6) of 2nd gear and needle bearing

Remove retaining ring (7)

Detach thrust washer halves

Remove 2x slotted needle bearings (9)

Remove 3rd gear (10) synchronizer ring

Remove retaining ring synchro body 3rd/4th gear using KM-396 (11)

Remove spacing ring from synchro body




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Differential Case Disassemble

Special Tools

Differential, Dismantle (F17+/ F17+ MTA)

KM-161-BBearing Puller

KM-303Removal Sleeve

KM-304Remover

KM-451Remover/Installer

KM-454-BRemover/Installer

KM-458-BMounting Drift





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1. Remove 2x axle shaft seal ring from bearing race (3) and transmission.

Remove axle shaft seal ring with KM-454-B-2 (1) and KM-454-B-4 (2).

I mportant: Only necessary when replacing the bearing in the bearing race.

2. Remove tapered roller bearing outer race from bearing race.

I mportant: Only necessary when replacing the bearing in the transmission.

Place tapered roller bearing outer race on KM-303 (6)

Remove tapered roller bearing outer race with KM-304 (4) and KM-451 (5)




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3. Remove tapered roller bearing outer race from transmission.

Remove tapered roller bearing outer race with KM-304and KM-451.

I mportant: Only necessary when replacing.

I mportant: Do not interchange outer and inner races respectively when re-using tapered

roller bearings.

4. Detach 2x tapered roller bearing inner race (1) from differential.




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For overhauling work, the speedometer gear (driving) (5) should be destroyed, if still

present. On assembling, it is not reinstalled.

Remove tapered roller bearing inner race with KM-161-B (2), KM-161-B-3 (4) and KM-161-

B-4 (3).

I mportant: Use protective jaws.

5. Remove the ring gear from the differential housing.

Clamp differential housing in vice.

6. Dismantle differential housing.

7. Clean all parts and transmission housing.

8. Check all parts for damage. Replace damaged components.

Detach 2x retaining ring (2) from tapered axle

Remove tapered axle

Remove axle shafts and tapered differential gears with KM-458-B

Remove plastic cage




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Gears Cleaning and I nspection

Check gears. Replace damaged components.

(1) 4th gear

(2) 3rd Gear

(3) 1st Gear

(4) 2nd Gear





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Synchronizers Cleaning and I nspection

Check synchro body assembly. Replace damaged components. Synchro body assembly, 5th gear, is

removed in the course of the operation Transmission Case Disassemble and installed in the course

of the operation Transmission Case Assemble.

Check synchronizer rings. Replace damaged components.

(1) 3rd/4th gear synchro body assembly(2) 1st/2nd gear synchro body assembly





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(1) 4th gear synchronizer ring

(2) 3rd gear synchronizer ring

(3) 1st gear inner synchronizer ring

(4) 1st gear intermediate ring

(5) 1st gear outer synchronizer ring

(6) 2nd gear outer synchronizer ring

(7) 2nd gear intermediate ring

(8) 2nd gear inner synchronizer ring




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Output Shaft Assemble

Special Tools

Main Shaft, Assemble ( F17+/ F17+ MTA)

KM-307-BRemover Plate

KM-396Ring Pliers





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I mportant: Synchronizer ring lugs must be aligned with synchro body grooves.

3. Attach synchro body assembly 3rd/4th gear.

4. Fit 3rd gear.

Position 4th gear synchro ring (3) and synchro body assembly (2) on 4th gear (4)

I mportant: Groove on slider sleeve (arrow) points to 4th gear.

Press synchro body assembly (6) and 4th gear (5) on to main shaft

Locate spacing ring on synchro body

I mportant: Use new retaining ring.

Attach retaining ring with KM-396 (3) - Retaining ring must sit in groove correctly

Locate synchronizer ring 3rd gear (2) on synchro body assembly

Attach 2x slotted needle bearings (1) to main shaft




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I mportant: Lugs of the synchro rings must be flush with the grooves of the synchro body

and the gear wheel.

5. Attach synchro body assembly 1st/2nd gear.

6. Secure synchro body assembly 1st/2nd gear (3).

I mportant: Retaining ring must sit in groove correctly.

7. Insert new retaining ring (1) using KM-396 (2).

8. Attach 1st gear (5).

Locate 3rd gear (5) on main shaft

Fit both halves of the thrust washer (arrows) and retaining ring (4) using grease

Place needle bearing on main shaft

Locate synchro body 1st/2nd gear (6) with inner synchro ring (9), intermediate ring (8)

and outer synchro ring (7) on gear wheel for 2nd gear (10)

Press synchro body assembly 1st/2nd gear (12) on to main shaft with 2nd gear (11)




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9. Fit thrust washer 1st gear (4).

Press thrust washer onto main shaft (11) using KM-307-B.

10. Visually check main shaft. All gears must turn freely.

Locate slotted needle bearing (6) on main shaft

I mportant: Lugs of the synchro rings must be flush with the grooves of the synchro

body and the gear wheel.

Locate 1st gear with inner synchro ring (9), intermediate ring (8) and outer synchro

ring (7) on synchro body assembly 1st/2nd gear (10)




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Notice: Refer to Fastener Noticein the Preface section.

I mportant: Replace drive gears only in pairs (driving and driven). Note identification groove

(arrows) running around tip of tooth.

3. Attach ring gear (1).

TightenTighten 8x new bolts a first pass to 70 Nm (52 lb ft).

Tighten

Tighten the bolts a second pass 30 degrees.

Tighten

Tighten the bolts a final pass 15 degrees.

Center differential pinions with KM-456 (2)

Install tapered axle (6)

Attach 2x new retaining ring (4) and (5)




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4. Attach 2x tapered roller bearing inner race (2).

Attach tapered roller bearing inner race with KM-453 (1) to differential housing (3).




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Transmission Case Assemble

Special Tools

KM-113-2Bracket


KM-446Installer Drift


KM-454-BRemover/Installer

KM-473Sleeve


KM-552Fixture

KM-982Mount

KM-6037Adapter KM-6115Bracket for Clutch Housing

KM-6155Guide Pins

KM-6157Assembly Sleeve

KM-6336Installer

KM-6337Installer

KM-6338Installer

KM-6339Installer

MKM-536-AFriction Coefficient Meter





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1. Attach new transmission housing to KM-6115.

2. Fit roller bearing (3) for main shaft.

Install roller bearing flush in transmission housing with KM-454-B-3 (5) and KM-454-B-

4 (4).

I mportant: Needle bearing side with writing points to transmission.

3. Fit needle bearing (2) for drive shaft.

Install needle bearing flush in transmission housing with KM-454-B-2 (6) and KM-454-B-

4 (1).

4. Insert differential into transmission from below.

I mportant: Align bearing race with marking previously made.

5. Install bearing race with KM-447 (2).

I mportant: The connection must be oil-tight.

6. Coat thread (arrow) and new O-ring (1) with multi-purpose grease.




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7. Check clearance between tapered roller bearing and differential housing (external LU).

I mportant: Adjust bearing pre-tension by screwing in bearing race.

8. Check breakaway torque with MKM-536-A (1) and KM-6037 (2).

I mportant: Adhere to specified breakaway torques.

9. Test rpm 1 revolution per second.

Breakaway Torque

60...100 Ncm

Breakaway Torque150...210 Ncm

10. Clean thread for retaining plate bolt in transmission housing.

Notice: Refer to Fastener Noticein the Preface section.

I mportant: Insert bolt with locking compound.

11. Attach retaining plate for bearing ring.

12. Re-cut thread.

Tighten

Tighten bolt 9 Nm (80 lb in).

Re-use all the dismantled parts. Adjust to marking.

Re-use bearing, replacement of bearing race, bearing flange, differential or transmission

housing.

Bearing as new part




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I mportant: Note seating and condition of the O-ring (2). Damage to or absence of the O-

ring leads to leaks.

13. Install fastening sleeve for pressure line (1). The lug (arrow) on the sleeve must sit in the

groove in the clutch housing.

14. Engage pressure line in fastening sleeve.




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Tighten

Tighten bolt to 5 Nm (44 lb in)

17. Attach pressure line (1).

Tighten

Tighten retaining nut 14 Nm (10 lb ft).




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I mportant: Check shaft for proper seating.

20. Fit main and drive shafts.

Place main shaft (1) and drive shaft (4) on KM-6337 (5)

Place end shield (3) on main shaft and drive shaft and press on with KM-6338 (2)




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21. Fit 5th gear bearing sleeve (1).

Locate end shield on KM-6337 (3)

Press bearing sleeve on main shaft using KM-6339 (2)




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I mportant: Note installation position.

22. Fit reverse gear axle (1).

Locate reverse idler on axle -- note installation position, shift fork groove to top

Press reverse gear axle with inserted lock ball (arrow) to stop in end shield




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25. Fit locking pin (5). Insert 3rd/4th gear and reverse gear locking pins.

I mportant: To relieve pressure on gearshift rod guides in end shield, support gearshift rods

with wooden wedge (1) when securing with pin.

26. Fit reverse gear shift fork.

Insert reverse gear shift fork (6) and gearshift rod

Insert new roll pin using KM-308 (arrow) -- allow new roll pin to protrude approximately

2 mm (0.08 in)




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with wooden wedge (2) when securing with pin.

27. Fit 1st/2nd gear shift fork.

Insert 1st/2nd gear shift fork (4) and gearshift rod (1)

Insert new roll pin using KM-308 (3) -- allow new roll pin to protrude approximately

2 mm (0.08 in)




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28. Insert 5th gear (4) shift driver.


with wooden wedge when securing with pin.

29. Fit 3rd/4th gear shift fork.

30. Fit locking plugs.

Install 4x locking plugs (5-7) -- drive to stop with plastic hammer or soft metal drift.

31. Bring gear shift fork into neutral speed position.

Insert 3rd/4th gear shift fork (2) and gearshift rod (1)

Insert new roll pin using KM-308 (3) -- allow roll pin to protrude approximately 2 mm

(0.08 in)




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32. Engage gear 3x.

33. Attach bridge (2) for locking bolt on end shield.

I mportant: Coat bolts with locking compound

34. Screw in 2x new bolt.

35. Move gearshift fork 1st/2nd gear into neutral.

36. Fasten 2x bolt for bridge.

Tighten

Tighten 2x bolt for bridge 7 Nm (62 lb ft)

37. Bring shift fork into neutral position.

38. Attach bearing support (4) to end shield with pawl (3).

I mportant: Coat bolts with locking compound.

39. Tighten 2x bolt.

Tighten

Tighten 2x bolt 9 Nm (80 lb ft).

Engage 2nd gear

Engage 3rd gear

Engage 5th gear




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I mportant: Note installation direction. Long gear hub points to end shield.

40. Install 5th gear (driven) (2).

41. Fit 5th gear (5) (driven).

Insert end shield with main and drive shafts in KM-6337 (3)

Press on 5th gear using KM-473 (1)

I mportant: Retaining ring must engage completely.

fit new retaining ring

I mportant: Ensure correct seating of slotted needle bearings.

Coat needle bearings (6) with transmission fluid and place on main shaft

Locate 5th gear and 5th gear synchronizer ring on main shaft




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42. Press on 5th gear synchro body assembly.

43. Fit bearing support with rocker arm.

Insert end shield in KM-6337

I mportant: Synchronizer ring lugs must be aligned with synchro body grooves.

Place synchro body assembly (1) on main shaft

Press synchro body in KM-473on to main shaft

I mportant: Retaining ring must engage completely

fit new retaining ring

Insert 2x crosshead shoes (arrow) in 5th gear shift fork (3)

Insert bearing support with rocker arm in end shield

Insert 2x bolts with locking compound

Tighten 2x bolt




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Tighten

Tighten 2x bolt 22 Nm (16 lb ft)

44. Install friction washer and magnet.

Fit friction washer (arrow) on axle, reverse gear wheel, with grease

Insert magnet with grease

I mportant: Before installing end shield, check following items for position and

seating:

40.1. 3rd/4th gear shift fork

40.2. 3rd/4th gear shift rod

40.3. 5th gear shift driver

40.4. 1st/2nd gear shift rod

40.5. Lock pin for gear stop

40.6. 1st/2nd gear shift fork




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45. Detach end shield from KM-113-2. Detach end shield from KM-552.

46. Attach KM-6155to transmission.

47. Stick new end shield gasket to transmission with roller bearing grease.

I mportant: Check that magnet (1) and friction washer (2) are correctly seated.

48. Install end shield (4).

TightenTighten 4x bolt (arrows) 22 Nm (16 lb ft)

49. Unscrew KM-6155 (3).

40.7. Reverse gear shift fork

40.8. Reverse gear shift rod

Carefully insert end shield into transmission housing

Use new bolts




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I mportant: Note close tolerance bolts.

50. Attach end shield cover.

Tighten

Tighten 4x bolt M7 15 Nm (11 lb ft)

Tighten

Tighten 5x bolt M8 20 Nm (15 lb ft)

Attach with new gasket to transmission housing

Tighten 4x bolt M7

Tighten 5x bolt M8




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I mportant: Coat seal ring with grease.

51. Drive new seal ring with matching sleeve (1) flush into housing.52. Push gearshift rod into gearbox cover and gearshift finger.

I mportant: Allow roll pin to protrude approximately 2 mm (0.0787 in)

53. Drive new roll pin into gearshift finger and gearshift rod.

I mportant: Gearshift finger must sit in gearbox intermediate lever.




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54. Insert intermediate gearshift lever into gearbox cover.

55. Place washer (5), spring (4) and sleeve (3) on gearshift lever shaft.

Fit new retaining ring (2).

56. Attach gearbox cover to KM-982.

I mportant: Guide bolt must sit in connecting link.

57. Drive guide bolt for connecting link (2) in gearbox cover.

I mportant: Do not damage engaging sleeve.




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58. Drive engaging sleeve for intermediate shaft (1) with matching sleeve (3) into gearbox

cover.59. Detach gearbox cover from KM-982.

60. Attach gearbox cover (1) to transmission.

Tighten

Cement new gasket to transmission housing with grease

I mportant: Adjusting pin must sit in adjusting bore and lock the gearbox.

Place gearbox cover on transmission

Tighten 4x bolt




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Tighten 4x bolt 15 Nm (11 lb ft)

I mportant: Use new seal ring.

61. Fit reversing lamp switch (1).

Tighten reversing lamp switch (1).

Tighten

Tighten reversing lamp switch 20 Nm (15 lb ft)

Draw adjusting pin (2) out of adjusting bore




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