Assembly Features of a 5-speed Gearbox (Opel Kadett E)

After installing the synchronizer of the 1st and 2nd gears on the secondary shaft, perform the following operations:

• install the 1st gear pinion and needle bearing on the shaft;
• install a retaining ring and thrust washer on the bearing with the chamfer facing the bearing:
• holding the retaining ring in a compressed state using a device made from improvised materials (see photo), install the secondary shaft into the hole in the intermediate crankcase;
• install the primary and secondary shafts, as well as the rod and fork for shifting I-II gears, into the holes of the intermediate crankcase;
• install the reverse gear engagement rod and fork, the 5th gear engagement slider and the 3rd-4th gear engagement rod and fork;
• install the retaining bracket on the intermediate housing, screw in new bolts with heads that have capsules with a locking compound, and tighten them;
• install the 5th gear engagement fork bracket with the stopper on the intermediate housing so that one of the locking protrusions of the stopper is located opposite the cutout of the 3rd-4th gear shift rod, install and tighten new mounting bolts with heads that have capsules with a locking compound;
• install 8 intermediate crankcase four plugs retainers with seals; one long plug of the III and IV gear shift rod retainer and three short plugs;
• assemble the intermediate case completely using the KM 554 device. To do this, press on the large V-gear pinion with the protruding part of the hub towards the ball bearing using the KM 466 3 device. Using the KM 334 device, press on the V-gear synchronizer, preheating the synchronizer to 100°C, monitoring the heating temperature with a thermochromic pencil. The synchronizer spring should be on the gear side. Replace the retaining rings with new ones;
• install the bracket on the intermediate housing, tighten the new mounting bolts with the capsule with the locking compound and tighten them to the specified torque;
• install a fully assembled intermediate crankcase (without rear gearbox cover) onto the gearbox housing, screw in and tighten the mounting bolts to the specified torque;
• screw the cylindrical bolt into the rear end of the input shaft and push the shaft until it stops;
• carefully insert the input shaft into the gear block by hand;
• secure the shaft with a new retaining ring;
• install the rear cover of the gearbox onto the intermediate housing, screw in the mounting bolts and tighten them to the specified torque.

Further assembly of the 5-speed gearbox is carried out in the same way as the 4-speed gearbox.