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

1. Apply a thick layer of grease to secure the rollers in their separator and install the bearing on the driven shaft so that it fits against the main gear drive pinion.

2. Install the half-ring thrust washers so that their projections align with the holes in the shaft, and secure the washers with a retaining ring (see photo).





3. Install the split needle roller bearing (see photo).





4. Install the 4th gear pinion (see photo).



5. Install the cone ring of the 4th gear (see photo).



6. Install the 3/4 gear synchronizer so that the narrow groove on its sleeve is on the side away from the main gear drive pinion. Run the synchronizer along the shaft using a puller or a tube resting on the synchronizer hub (see photo).





7. Install the thrust washer (see photo).



8. Install the retaining ring (see photo).



9. Install the cone ring of the 3rd gear pinion (see photo).



10. Install the split needle roller bearing (see photo).





11. Install the 3rd gear.



12. Install the half-ring thrust washers and secure them with a retaining ring. Install the needle roller bearing (see photos).









13. Install the 2nd gear.



14. Install the cone ring of the 2nd gear (see photo).



15. Install the 1/2 gear synchronizer so that the teeth of the reverse gear on its clutch face the drive gear of the main gear. Drive or hammer the synchronizer into its place on the shaft (see photo).





16. Install a regular thrust washer (see photo).



17. Install the retaining ring (see photo).



18. Install the cone ring of the 1st gear (see photo).





19. Install the split needle roller bearing and then the 1st gear pinion (see photos).





20. Install the needle roller thrust washer.





21. Install a standard thrust washer so that the groove on its rim is positioned as shown in the photograph. This is necessary to provide the required clearance when the driven shaft bearing retaining ring is compressed to install the gear assembly into the intermediate plate. Place the large bearing retaining ring onto the shaft (see photo).





22. Install the ball bearing on the driven shaft so that the closed side of the bearing is visible after installation (see photo).



23. Place the driven shaft bearing retaining ring in the groove on the thrust washer, squeeze the ends of the ring together and install the temporary clamp (see section 18, paragraph 23).

24. Release the ends of the drive shaft retaining ring (see photo).



25. With someone's help, engage the gears of the driven and driving shafts and the intermediate gear of the reverse gear, which will have to be held by hand (the groove for the gear shift fork must be on the side of the main gear drive pinion) (see photo).



26. Install the gear blocks together with the reverse intermediate gear into the intermediate plate. Loosen the drive shaft bearing retaining ring and remove the clamp holding the driven shaft bearing retaining ring in the compressed position.

27. Install the 1/2 gear rod and fork and secure the fork to the rod with a cylindrical pin (see photos).





28. Install the reverse gear rod and fork and secure the fork to the rod with a cylindrical pin (see photo).



29. Install the 5th gear rod linkage into the intermediate plate.

30. Install the 5th gear rod dog and the 3/4 gear fork and insert the rod into them (see photos).





31. Secure the 3/4 gear fork to its rod with a new cylindrical pin (see photo).



32. Insert the locking rod into the hole in the intermediate plate.



33. Install the locking plunger jumper. The jumper mounting screws can only be tightened after the 2nd gear pinion and the 5th gear rod have been moved to the gear engagement positions (see photos).





34. Insert the 5th gear pawl into the slot on the leash and then secure the pawl to the intermediate plate with bolts (see photo).





35. Insert the plungers of the locks together with their springs into the holes in the intermediate plate (see photos).







36. Hammer the locking plugs back into place, noting that the 3/4 gear locking plug is longer than the other three (see photo).



37. Install the thrust washer (one that has a central hole with flat sides) to the axis of the intermediate reverse gear. Secure the washer in place with grease (see photo).



38. Install the magnet (clean) into the slot provided for it on the intermediate plate (see photo).



39. Install a new gasket on the gearbox housing flange and lower the intermediate plate into the housing together with the gear block (see photo).



40. As the gear block lowers, engage the drive gear of the main transmission with the driven gear (see photo).



41. Screw in the mounting bolts.

42. If the drive shaft was pulled out of the gear block, it must now be put back in place (see photo).



43. Install the 5th gear on the end of the drive shaft and secure it with a retaining ring (see photos).





44. Install semi-ring thrust washers with a retaining ring on the end of the driven shaft (see photos).





45. Install a split needle roller bearing on the driven shaft (see photo).



46. Install the 5th gear on the driven shaft (see photo).



47. Install the cone ring of the 5th gear.



48. Install the 5th gear synchronizer so that the side from which the movable keys are visible is directed towards the 5th gear pinion (see photo).



49. Install the retaining ring (see photo).



50. Move the 5th gear to the engaged position and install the fork with the hinge screw. Tighten the Allen head screws (see photo).



51. Install the screw and retaining ring onto the end of the drive shaft. The retaining ring is located in a groove deep in the recess at the end of the shaft, and you will need special pliers to work with it (see photos).





52. Install the end cover with a new gasket and secure it with bolts (see photos).





53. Screw the screw plug into the end cap (if it was filmed) (see photo).



54. Install the gearshift cover with a new gasket so that the shift fingers engage with the pawls (the box must be in neutral position). Insert and tighten the mounting bolts (see photo).



55. Fasten the main gear cover with bolts.

56. Fasten the flywheel housing cover with bolts (see photo).



57. Check that all gears are engaged (see photo).



58. Install the box on the car and fill it with oil.