Gearbox type F16.5 — disassembly (Opel Ascona C)

Note: The operations specified in paragraphs 6 and 7 must be performed during the removal of the box, and are listed here only to create a complete picture of the disassembly of the box.

1. Remove the box from the car and clean it from the outside from dirt with kerosene or a water-soluble solvent and a stiff brush.

2. Loosen the bolts securing the final drive housing cover and allow the oil to drain.

3. Loosen the bolts and remove the flywheel housing cover.

4. Loosen the bolts, remove the gearshift mechanism cover and tear off the gasket from the flange.

5. Unscrew the bolts and remove the end cover of the box with its gasket.

b. Remove the exposed retaining ring from the end of the drive shaft. This ring is located quite deep in its groove and special pliers are required to remove it.

7. Unscrew and remove the screw with a 12-sided hole in the head (you can use a suitable Allen key for this).

8. Unscrew the bolts and disconnect the main crankcase from the intermediate plate.

9. Using a hex key, loosen the screws securing the 5th gear fork. The work will be easier if you first manually move the 5th gear synchronizer to the engaged position.

(Original posted on the website: opelbook)

10. Remove the retaining ring from the end of the driven shaft and, using a two-support puller, remove the 5th gear pinion and synchronizer from the shaft. The puller jaws must be positioned under the 5th gear pinion.



11. Remove the retaining ring from the end of the drive shaft and remove the 5th gear (large) gear from the shaft. To remove the gear, you can use two tire irons, pressing the gear with them like levers (see photos).





12. Using a hex key, loosen the screws securing the 5th gear rod locking pawl to the intermediate plate.

13. Using a fork-pry or a slide hammer, remove the retainer plugs from the edge of the intermediate plate. Be prepared to catch the springs that pop out after removing the plugs. Pull out the plungers of the locks (see photos).









14. Plugs damaged during removal must be replaced.

15. Move the 5th gear rod to the engaged gear position.

16. Move the 2nd gear fork to engage 2nd gear.

17. Using a hex key, loosen the screws securing the locking plunger jumper. Remove the jumper.

18. Return the gears to neutral position.

19. Drive out the cylindrical pin securing the 3/4 gear fork. Remove the rod and fork. Remove the reverse gear rod and fork in the same manner.

20. Pull the locking rod out of the intermediate plate.

21. Remove the 5th gear rod link from the intermediate plate.

22. Drive out the cylindrical pin and remove the fork and 1/2 gear rod.



23. Press together the ends of the large retaining ring that secures the driven shaft bearing to the intermediate plate. Make a clamp from a thin rod and fix the retaining ring in a compressed state.



24. Spread the ends of the retaining ring that holds the drive shaft bearing in the intermediate plate.

25. Together with an assistant, pull out the gear blocks together with the reverse intermediate gear. It may be necessary to tap the shafts with the bearings with a plastic hammer to get them out of the intermediate plate. Note the washer on the reverse intermediate gear.

Drive shaft and gear block

26. Inspect the gear teeth for wear. If the teeth are clearly worn, the gear block must be replaced (see photo).





27. Bearings can be replaced using a suitable puller.

28. The shaft can be knocked out of the gear block using a hammer with a plastic striker.

Driven shaft

29. Place the jaws of the two-support puller under the 1st gear pinion and remove the pinion together with the ball bearings from the driven shaft (see photo).



30. Remove the retaining ring. Remove the regular thrust washer from the shaft and then the needle thrust washer.

31. Remove the cone ring of the 1st gear.

32. Remove the split needle roller bearing.

33. Remove the retaining ring.

34. Remove the regular thrust washer.

35. Place the puller jaws under the 2nd gear pinion and remove the 1/2 gear synchronizer with the reverse gear pinion, the cone ring and the 2nd gear pinion from the driven shaft. Note that the reverse gear teeth on the synchronizer sleeve face the end of the shaft on which the main gear pinion is located.

36. Remove the half-ring thrust washers and their retaining ring.

37. Remove the 3rd gear.




38. Remove the cone ring of the 3rd gear.

39. Remove the split needle roller bearing.

40. Remove the retaining ring securing the 3/4 gear synchronizer.

41. Remove the thrust washer.

42. Place the puller jaws under the 4th gear pinion and remove the 3/4th gear synchronizer, cone ring and 4th gear pinion from the driven shaft.

43. Remove the split needle roller bearing.

44. Remove the half-ring thrust washers and their retaining ring.

45. Remove the roller bearing ring from the shaft. The main gear pinion is not removed.

Synchronizers

46. See section 13.

Gearbox housing

47. See section 10 and photograph.

Gear shift cover

48. See section 9.

Differential and final drive.

49. Removal, installation and adjustment of the differential and final drive are carried out in the same way as described in sections 8 and 14.