Secondary shaft of a manual gearbox — disassembly and assembly (Opel Omega A)

1. Remove the 4th synchronizer ring from the 3/4 gear synchronizer. Mark the position of the ring.

2. Pull the speedometer drive gears off the rear of the secondary shaft (photo).



3. Using pliers, remove the retaining ring from the front end of the secondary shaft (photo).



4. Using an extractor, remove the 3/4 gear synchronizer and 3rd gear gear (photo). Also remove the 3rd gear needle bearing.



5. Separate the 3/4 gear synchronizer from the 3rd gear pinion and remove the 3rd gear synchronizer ring. Mark the position of the synchronizer ring.



6. Remove the support ring, then release the two halves of the thrust washer (photo).





7. Remove the 2nd gear pinion and the 2nd gear synchronizer ring. Also remove the 2nd gear needle bearing (photo).







8. Use pliers to remove the retaining ring securing the 1/2 gear synchronizer (photo).





9. Using an extractor, remove the 1/2 gear synchronizer and 1st gear gear (photo). Also remove the needle bearing.



10. Separate the 1/2 gear synchronizer from the 1st gear pinion and remove the 1st gear synchronizer ring. Mark the position of the ring.

11. Using an extractor, remove the ball bearing from the rear of the secondary shaft (photo).



12. Remove the bearing retaining ring (photo).





13. Remove the 5th gear pinion, 5th gear synchronizer ring and needle bearing (photo).







14. Using pliers, remove the retaining ring securing the 5/3 gear synchronizer (photo).





15. Using an extractor, remove the reverse gear pinion together with the 5/3 gear synchronizer from the rear of the secondary shaft (photo). Separate the pinion from the synchronizer and remove the reverse synchronizer ring.



16. Remove the roller bearing from the secondary shaft (photo).



17. If necessary, the synchronizers can be disassembled as follows.



18. Remove the springs from each side of the synchronizer (photo).



19. Mark the synchronizer hub and sleeve relative to each other, then pull the sleeve off and remove the sliding keys.

20. Clean all components, inspect them for wear and damage, replace as necessary.

21. Assembly begins with the synchronizers as follows. Pull the sleeve onto the hub, aligning the marks made earlier. The cuts in the sleeve should match the grooves of the sliding key on the same side (photo).



22. Insert the sliding keys into the grooves, then install the springs (photo). Note that the spring for the 4th synchronizer ring is approximately 10.0 mm longer.





23. Place the reverse gear roller bearing on the secondary shaft, then the reverse gear and reverse synchronizer ring (photo).









24. Heat the 5/3 gear synchronizer to approximately 100°C. Immediately place the synchronizer on the secondary shaft grooves using an extractor, making sure that the sliding keys enter the grooves in the synchronizer ring (photo).





Original posted on the website (www.OpelBook.ru)



25. Install the retaining ring into the groove.

26. Install the 5th gear needle bearing, 5th gear synchronizer ring and 5th gear (photo). Make sure that the sliding keys fit into the grooves of the synchronizer ring.



27. Position the bearing retaining ring over the 5th gear. Alternatively, the retaining ring can be held in the compressed position with a piece of wire (photo).



28. Using an extractor, place the bearing on the secondary shaft with the closed side facing the gear (photo).



29. Install the 1st gear needle bearing, then the 1st gear and the 1st gear synchronizer ring (photo).





30. Heat the 1/2 gear synchronizer to approximately 100°C. Immediately press the synchronizer onto the secondary shaft grooves using an extractor, making sure that the sliding keys engage the grooves in the synchronizer ring. The identification groove on the sleeve should face the front end of the secondary shaft (photo).



31. Install the retaining ring into the groove.

32. Install the 2nd gear needle bearing, then the synchronizer ring and 2nd gear. Make sure that the sliding keys fit into the grooves in the synchronizer ring.

33. Install the two halves of the thrust washer and secure them with a ring.

34. Install the 3rd gear pinion needle bearing, then the pinion and 3rd gear synchronizer ring (photo).







35. Heat the 3/4 gear synchronizer to approximately 100°C. Immediately press the synchronizer onto the secondary shaft grooves using an extractor. Make sure that the sliding keys engage the grooves in the synchronizer ring. The identification grooves on the sleeve should face the front end of the secondary shaft (photo).



36. Install the retaining ring into the groove.

37. Place the 4th gear synchronizer ring into the 3/4 gear synchronizer.

38. Place the speedometer drive onto the rear of the secondary shaft.