Driven shaft (type F10 and F 10.4 boxes) — overhaul (Opel Ascona C)

To perform the following operations, you may need a hydraulic press or a heavy-duty puller.

Note: Before pressing the shaft out of the gears, synchronizers, etc., the parts to be released should be securely supported. Similarly, if a puller is used, it should be checked that its jaws are on the body of the part being removed and under no circumstances on the teeth, for example, of a gear. In extreme cases, if the part does not go well, it can be carefully heated, but not more than 100°C.

1. Remove the retaining ring from the bearing at the end of the shaft (see photo).



2. Support the 1st gear pinion and drive the shaft out of the bearing and out of the pinion. Note the spacer washer between the bearing and the gears (see photos). Some recent models have a radial needle bearing installed instead of a spacer washer. In this case, it is necessary to remove both this bearing and the gear bearing.

Note: Some models may have a needle bearing instead of a spacer washer.

3. Support the 2nd gear and remove the retaining ring securing the 1/2 gear synchronizer (see photo).





4. Remove the conical ring from the shaft (see photo).



5. Secure the puller or press plate under the 2nd gear.

6. Press out or remove the 2nd gear and the 1/2 gear synchronizer from the shaft.

7. Disconnect the 2nd gear from the synchronizer and remove the 2nd gear cone ring.

8. Go to the other end of the shaft and remove the retaining ring securing the main drive pinion to the shaft (see photo).



9. Remove the drive gear (see photo).





10. Remove the spacer washer (see photo).



11. Remove the 4th gear (see photo).



12. Remove the cone ring (see photo).



13. Remove the retaining ring securing the 3/4 gear synchronizer to the shaft (see photo).





14. Remove the 3/4 gear synchronizer (see photo).



15. Remove the next cone ring (see photo).



16. Remove the 3rd gear pinion (see photo).





17. Inspect all gears for damaged or worn teeth, and the shaft for worn splines.

18. Replace all retaining rings. Compare new parts with old ones to ensure they are identical. This is especially important when replacing the following parts, which were modified in April 1986:

• a. The 1st gear cones have been increased in diameter to 58 mm from the previous 51 mm. The 1st gear fork, which is not interchangeable with the fork on earlier models, has been similarly modified.
• b. Ball bearings with mounting grooves became closed (previously open type bearings were used).
• c. On the F10.4 gearbox, 2 modifications have been made to the 1st gear pinion. The pinion now rests on a needle bearing with a split separator, and in addition, a radial needle bearing has been installed instead of a spacer washer (see insets in Figure 6.19).

19. If gear shifting was accompanied by noise or the synchronizers did not work well, the synchronizers should be replaced as a whole or overhauled (see next section).

20. Clean and oil all parts, then assemble them in the sequence shown below. If necessary, parts should be pressed onto the shaft using a tube of suitable size, which would rest on the body of the part and not on its teeth.



21. Install the 3rd gear pinion on the end of the shaft where the main gear pinion is located.

22. Install the cone ring on the cone of the 3rd gear.

23. Install the 3/4 gear synchronizer (pressure must be applied to its hub) (see photo). It is recommended to preheat the synchronizer to 100°C.



24. Secure the synchronizer with a new retaining ring.

25. Install the cone ring and 4th gear.

26. Install the spacer washer and the final drive pinion. It is recommended to preheat both of these parts to 100°C.

27. Secure the main gear pinion with a new retaining ring.

28. Go to the other end of the shaft and install the 2nd gear gear (see photo).





29. Install the cone ring on the cone of the 2nd gear.



30. Heat the 1/2 gear synchronizer to 100°C and press it onto the shaft with the reverse gear teeth facing the 2nd gear gear (see photo).



31. Secure the synchronizer with a new retaining ring.

32. Install the 1st gear cone ring and the 1st gear itself.

33. Heat the spacer washer to 100°C and press it onto the shaft with the grooves towards the 1st gear (see photo).



34. Place a new retaining ring on the shaft so that it is ready to be installed in its groove on the gearbox housing.

35. Install the bearing and secure it with a new retaining ring.

(Original source is on the website: opelbook)