Features of disassembling a 5-speed gearbox (Opel Kadett E)

After removing the reverse light switch, proceed as follows.

Remove the rear gearbox cover.

Loosen the bolts securing the intermediate case to the gearbox case and remove the intermediate case together with the primary and secondary shafts.

Install the intermediate crankcase on the KM 113 2 support with the KM 552 device.

Loosen the mounting bolts and use a lever to separate the 5th gear fork mounting bracket from the intermediate housing.

Turn on two gears at the same time (for example, 3rd gear and reverse gear), remove the retaining ring installed in front of the 5th gear synchronizer and remove the 5th gear synchronizer from the secondary shaft using the KM 161 A puller and KM 161 2 hooks.



Remove the 5th gear from the secondary shaft, the split needle bearing by slightly loosening it, the retaining ring of the thrust half rings and the thrust half rings.

Remove the retaining ring installed in front of the 5th gear drive pinion and, using the KM 553 puller, remove the 5th gear pinion from the input shaft.

Remove the bearing support together with the stopper from the intermediate housing. If it is necessary to replace the stopper, knock the axle out of the support.



Using devices KM 458, KM 328 1 and KM 328 5, remove four retainer plugs and retainer springs from the intermediate crankcase.



Simultaneously engage 2nd and 5th gears, unscrew the bolts securing the fixing bracket.

Engage 3rd gear and remove the retaining clip.

Remove the rod and fork for shifting III-IV gears, as well as the rod and fork for engaging reverse gear from the intermediate housing.

Remove the 5th gear engagement fork.

Remove the retaining rings from the primary and secondary shafts. Remove the secondary and primary shafts with the reverse intermediate gear, the fork and rod for shifting the first and second gears, and the fifth gear engagement slider.

Otherwise, disassembling a 5-speed gearbox is carried out in the same way as disassembling a 4-speed gearbox.

Warning. The hubs of the synchronizer clutch of the I-II, III-IV gears are fixed with a locking ring and a washer, all needle bearings of the shafts are of the split type. A thrust needle bearing is installed in front of the driven gear of the I gear.