Repair Instructions - Off Vehicle

2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission - F17-5 |
Repair Instructions - Off Vehicle | Document I D: 2004044

Transmission Case Disassemble
Special Tools

KM-113-2 Bracket
KM-308 Remover/Installer
KM-328-B Remover
KM-500-A Remover/Installer
KM-552 Fixture
KM-553-A Fifth Gear Puller
KM-556-A Puller Set
KM-557-A Remover
KM-559-A Puller
KM-727 Remover
KM-982 Mount
KM-983 Remover
KM-6115 Bracket for Clutch Housing
KM-6155 Guide Pins
KM-6335 Thrust Piece
MKM-559 Inner Extractor
2010 General Motors Corporation. All rights reserved.
Page 1 of 23 Document ID: 2004044
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1. Attach transmission to KM-6115 (2).
2. Attach transmission to KM-113-2 (1) using KM-6115 .
3. Remove left engine damping block bracket.
Remove 3x bolts.
4. Put transmission into neutral.
I mportant:Shift transmission to neutral position.
5. F17+ MTA: Remove gearshift module. Refer to Transmission Control Replacement.
F17+: Complete the following procedure:


Unscrew 4x bolt.
5.1. Press adjusting pin(2) into adjusting bore.
I mportant:The adjusting pin is at the front in the direction of travel.
5.1. Turn gearshift rod anti-clockwise (in direction of 3rd gear).
I mportant:Cover aperture in transmission.
5.2. Detach gearbox cover(1) from transmission.

5.3. Clean sealing surfaces, remove sealant residues.
5.4. Measure clearance(I) between alignment pin(2) and actuating mechanism(1) of the
gearshift rod 3rd/4th gear.
Measure with feeler gauge
Clearance must be approx. 0.5mm (0.0197in)
-
If clearance is too great, drive alignment pin further into the transmission housing
with a drift punch and measure clearance again.
-
If clearance is too small: No correction of clearance necessary because the gearshift

rod presses the alignment pin into the correct position.

Draw out of gearbox cover with KM-328-B (1) and KM-983 -2(2).
Draw out of gearbox cover with KM-328-B and KM-983 -1(4).
5.5. Attach gearbox cover to KM-982 (3).
5.6. Clamp KM-982 in a vice.
5.7. Remove engaging sleeve for intermediate lever from gearbox cover(I).
5.8. Remove guide bolt for connecting link from gearbox cover(II).
5.9. Detach retaining ring(5) from intermediate gearshift lever.

Turn gearshift rod(2) with gearshift finger in the direction of the arrow.
5.9.1. Remove bush(6)
5.9.2. Remove compression spring(7)
5.9.3. Remove washer(8)
5.10. Detach gearbox cover from KM-982 .
5.11. Remove intermediate gearshift lever(1).
5.12. Remove gearshift rod from gearbox cover.
Knock roll pin out of gearshift finger(3) with drift punch. Note recess in cover.

6. Unscrew reversing lamp switch(1).

I mportant:Place collecting pan underneath - transmission fluid will escape
7. Remove end shield cover.
I mportant:Do not further dismantle gearbox cover.
5.13. Prise seal ring(4) out of gearbox cover.
Unscrew 9x bolt. If necessary, release the end shield cover by striking it gently with a rubber
mallet.
Detach end shield cover gasket.

I mportant:When dismantling the end shield it is essential to use KM-6155 (2) as otherwise
the shaft seal ring of the central release will be damaged.
I mportant:Be careful of guide sleeves, magnet(3) and spacer washer(4) for axle reverse
idler gear.
8. Screw KM-6155 into threaded bores.
9. Detach end shield.
Unscrew 4x bolt (arrows).
10. Check all parts for damage. Replace damaged components.
11. Clean sealing surfaces.
12. Detach KM-6155 .

13. Attach end shield to KM-552 (2).
14. Attach end shield to KM-113-2 (1) using KM-552 .


I mportant:Micro-encapsulated fastening bolts. If fastening bolts are stiff, heat end shield
with hot-air dryer to approximately 80C (176F).
15. Remove bearing support(1) with rocker arm(2) from end shield.
Unscrew 2x bolt.

16. Remove 5th gear (driven).

Detach retaining ring from synchro body(1)
Pull gear wheel, 5th gear, and synchro body, 5th gear, away from main shaft with KM-
559-A (2)
Remove 2x needle bearing for gear wheel, 5th gear

17. Detach gear wheel, 5th gear (driving)(2) from drive shaft(3). Remove retainer(1).

I mportant:Ensure KM-553-A is correctly seated on the gear wheel, 5th gear (driving).
18. Detach gear wheel, 5th gear, (driving) from drive shaft with KM-553-A (1).
Place thrust piece(2) from KM-553-A on drive shaft.


19. Detach bearing support(2) with pawl(1) from end shield.
Remove 2x bolts (arrow).

20. Remove locking plugs (arrows) from end shield.
Remove locking plugs with KM-727 (2) and KM-328-B (1).

21. Detach bridge(1) for end shield locking bolt. The bridge will push out if 3rd gear is then
engaged.
22. Unscrew 2x bolt(2).
23. Engage 2nd gear and 5th gear.
Engage 2x gear with shift carrier (arrows).


I mportant:Relieve pressure on gearshift rod guides - for this, support gearshift rods above
with wood(1).
24. Remove shift fork, 3rd/4th gear and reverse gear.
25. Remove gear shift driver.
Remove 5th gear shift driver(4) from end shield.
26. Remove locking pins(5).
Remove roll pin for catch from end shield.

Drive roll pins out of 3rd/4th gear shift fork(3) and reverse gear shift fork(6) using KM-
308
Take out gearshift rod(2), gearshift rod reverse gear and shift fork

I mportant:Relieve pressure on gearshift rod guides - for this, support gearshift rods(1)
above with wooden wedge(2).
27. Remove 1st/2nd gear shift fork.

Drive roll pin(3) out of 1st/2nd gear shift fork(4) using KM-308
Take out shift fork with gearshift rod

I mportant:Collect main shaft, drive shaft and reverse idler.
28. Remove main shaft and drive shaft.
Detach end shield from KM-552
I mportant:To ensure that both shafts are pushed out evenly, press harder on the main
shaft side. Take care that the gear wheel, 1st gear, is not in contact with the press.
Press main shaft and drive shaft out as shown using KM-6335 (1)
Collect main shaft, drive shaft and reverse idler

I mportant:Note that retaining ball is released.
29. Remove reverse gear axle(1).
30. Remove bearing for main and drive shafts.
31. Clean all parts and sealing surfaces.
32. Check all parts. Replace damaged components.
I mportant: Use protective jaws
Clamp reverse gear spindle in vice
Carefully knock off end shield with brass punch
Remove 2x retaining rings(2)
Press out 2x bearings using KM-500-A -5(3)

I mportant:Place collecting pan underneath - transmission fluid will escape
33. Detach differential cover(1).
Unscrew 10x bolt.
34. Mark position of bearing race(2) in respect of transmission (arrow).

35. Remove bearing race with KM-447 (2).
Remove retaining plate(1) from bearing race - unscrew bolt.
36. Remove differential downwards.

37. Detach pressure line(1). Unscrew union nut.
38. Remove central release. Remove 3x bolt (arrow).

39. Check seal ring(1) on central release for damage. Replace damaged components.

40. Remove pressure line(1).
Unlatch fastening sleeve for pressure line on clutch housing (arrows)
Draw fastening sleeve with pressure line upwards and slightly out of transmission
Detach fastening sleeve for pressure line - carefully disengage retaining lugs(3)
Remove pressure line

42. Remove needle bearing(3) for drive shaft.
Remove needle bearing from transmission housing with KM-556-A (1) and MKM-559 (2).
43. Remove roller bearing(4) for main shaft.
Remove roller bearing from transmission housing with KM-556-A (6) and KM-556-A -2(5).

44. Remove 2x axle shaft seal ring with KM-557-A -1(2) and KM-557-A -2(1) from transmission
housing.
45. Remove transmission housing from KM-6115 .
Output Shaft Disassemble
Special Tools
Main Shaft, Dismantle ( F17+/ F17+ MTA)

1. Detach 1st gear(4).
2. Detach 3x synchronizer ring, gear wheel, 1st gear.
KM-307-B Remover Plate
KM-396 Ring Pliers
KM-736 Guide Bolt
Press 1st gear off main shaft with KM-307-B (2) and KM-736 (1)
Remove gear wheel, 1st gear, and thrust washer(3)
Remove needle bearing, inner synchronizer ring(5), intermediate ring(6) and outer
synchronizer ring(7).
3. Remove synchro body retaining ring.

4. Detach 2nd gear.
5. Detach thrust washer halves (arrows).
6. Remove 3rd gear gearwheel(8).
7. Remove retaining ring synchro body 3rd/4th gear.

Remove needle bearing
Remove retaining ring synchro body 1st/2nd gear using KM-396 (8)
Press synchro body assembly 1st/2nd gear and gear wheel for 2nd gear(1) off main shaft
with KM-307-B and KM-736
Remove shift sleeve 1st/2nd gear(2), outer synchro ring(3), intermediate ring(4) and
inner synchro ring(5) from gear wheel(6) of 2nd gear and needle bearing
Remove retaining ring(7)
Detach thrust washer halves
Remove 2x slotted needle bearings(9)
Remove 3rd gear(10) synchronizer ring
Remove retaining ring synchro body 3rd/4th gear using KM-396 (11)
Remove spacing ring from synchro body

8. Detach 4th gear.
I mportant:Open needle bearing
9. Detach needle bearing(5).
Remove 2x slotted needle bearings from main shaft.
10. Clean all parts.
I mportant:If gears are damaged, always check the gears of the gear cluster and replace
gear cluster if necessary.
Press off gear wheel, 4th gear(4), and synchro body with KM-307-B
Remove synchro body 3rd/4th gear assembly(2), synchro ring 4th gear(3) from 4th gear
Differential Case Disassemble
Special Tools
Differential, Dismantle ( F17+/ F17+ MTA)

KM-161-B Bearing Puller
KM-303 Removal Sleeve
KM-304 Remover
KM-454-B Remover/Installer
KM-458-B Mounting Drift

1. Remove 2x axle shaft seal ring from bearing race(3) and transmission.
Remove axle shaft seal ring with KM-454-B -2(1) and KM-454-B -4(2).
I mportant:Only necessary when replacing the bearing in the bearing race.
2. Remove tapered roller bearing outer race from bearing race.
I mportant:Only necessary when replacing the bearing in the transmission.
Place tapered roller bearing outer race on KM-303 (6)
Remove tapered roller bearing outer race with KM-304 (4) and KM-451 (5)
3. Remove tapered roller bearing outer race from transmission.
Remove tapered roller bearing outer race with KM-304 and KM-451 .

I mportant:Only necessary when replacing.
I mportant:Do not interchange outer and inner races respectively when re-using tapered
roller bearings.
4. Detach 2x tapered roller bearing inner race(1) from differential.
For overhauling work, the speedometer gear (driving)(5) should be destroyed, if still
present. On assembling, it is not reinstalled.
Remove tapered roller bearing inner race with KM-161-B (2), KM-161-B -3(4) and KM-161-
B -4(3).
I mportant:Use protective jaws.
5. Remove the ring gear from the differential housing.
Clamp differential housing in vice.

6. Dismantle differential housing.
7. Clean all parts and transmission housing.
Detach 2x retaining ring(2) from tapered axle
Remove tapered axle
Remove axle shafts and tapered differential gears with KM-458-B
Remove plastic cage
Gears Cleaning and I nspection
Check gears. Replace damaged components.

(1) 4th gear
(2) 3rd Gear
(3) 1st Gear
(4) 2nd Gear
Synchronizers Cleaning and I nspection
Check synchro body assembly. Replace damaged components. Synchro body assembly, 5th gear, is
removed in the course of the operation Transmission Case Disassemble and installed in the course
of the operation Transmission Case Assemble.

Check synchronizer rings. Replace damaged components.

(1) 3rd/4th gear synchro body assembly
(2) 1st/2nd gear synchro body assembly

(1) 4th gear synchronizer ring
(2) 3rd gear synchronizer ring
(3) 1st gear inner synchronizer ring
(4) 1st gear intermediate ring
(5) 1st gear outer synchronizer ring
(6) 2nd gear outer synchronizer ring
(7) 2nd gear intermediate ring
(8) 2nd gear inner synchronizer ring
Output Shaft Assemble
Special Tools
Main Shaft, Assemble ( F17+/ F17+ MTA)

KM-307-B Remover Plate
KM-396 Ring Pliers

I mportant:Lubricate rotating parts on their bearing, running, seating, and pressure
surfaces using transmission fluid. If a synchro body assembly has been completely
disassembled then the following method of procedure shall be observed for assembly.
1. Assemble synchro body.

2. Fit needle bearing(1).
Place 2x slotted needle bearing on main shaft and clip together.
Insert synchro body(1) into shift sleeve(2)
I mportant:Position at an angle and then press into the synchro body assembly.
Insert 3x thrust piece(3)
I mportant:Synchronizer ring lugs must be aligned with synchro body grooves.
3. Attach synchro body assembly 3rd/4th gear.

4. Fit 3rd gear.
Position 4th gear synchro ring(3) and synchro body assembly(2) on 4th gear(4)
I mportant:Groove on slider sleeve (arrow) points to 4th gear.
Press synchro body assembly(6) and 4th gear(5) on to main shaft
Locate spacing ring on synchro body
I mportant:Use new retaining ring.
Attach retaining ring with KM-396 (3) - Retaining ring must sit in groove correctly
Locate synchronizer ring 3rd gear(2) on synchro body assembly
Attach 2x slotted needle bearings(1) to main shaft
I mportant:Lugs of the synchro rings must be flush with the grooves of the synchro body
and the gear wheel.
5. Attach synchro body assembly 1st/2nd gear.

6. Secure synchro body assembly 1st/2nd gear(3).
I mportant:Retaining ring must sit in groove correctly.
7. Insert new retaining ring(1) using KM-396 (2).
8. Attach 1st gear(5).
Locate 3rd gear(5) on main shaft
Fit both halves of the thrust washer (arrows) and retaining ring(4) using grease
Place needle bearing on main shaft
Locate synchro body 1st/2nd gear(6) with inner synchro ring(9), intermediate ring(8)
and outer synchro ring(7) on gear wheel for 2nd gear(10)
Press synchro body assembly 1st/2nd gear(12) on to main shaft with 2nd gear(11)
9. Fit thrust washer 1st gear(4).
Press thrust washer onto main shaft(11) using KM-307-B .
10. Visually check main shaft. All gears must turn freely.
Locate slotted needle bearing(6) on main shaft
I mportant:Lugs of the synchro rings must be flush with the grooves of the synchro
body and the gear wheel.
Locate 1st gear with inner synchro ring(9), intermediate ring(8) and outer synchro
ring(7) on synchro body assembly 1st/2nd gear(10)
Differential Case Assemble
Special Tools
Differential, Assemble ( F17+/ F17+ MTA)

I mportant:Lubricate rotating parts on their bearing, running, seating, and pressure
surfaces using transmission fluid.
1. Install plastic cage in differential. It must be possible to insert the collar(1) of plastic cage
into the guide for the drive pinions in the housing.
2. Assemble differential housing.
KM-304 Remover
KM-446 Installer Drift
KM-453 Pusher
KM-456 Centering Drift
KM-458-B Mounting Drift
Insert drive and differential pinions in differential housing
I mportant:Use protective jaws
Clamp differential housing into vice with KM-458-B (3)
Noti ce: Refer to Fastener Notice in the Preface section.

I mportant:Replace drive gears only in pairs (driving and driven). Note identification groove
(arrows) running around tip of tooth.
3. Attach ring gear(1).
Tighten
Tighten 8x new bolts a first pass to 70Nm (52lbft).
Tighten
Tighten the bolts a second pass 30degrees.
Tighten
Tighten the bolts a final pass 15degrees.

Center differential pinions with KM-456 (2)
Install tapered axle(6)
Attach 2x new retaining ring(4) and (5)

4. Attach 2x tapered roller bearing inner race(2).
Attach tapered roller bearing inner race with KM-453 (1) to differential housing(3).


5. Attach 2x tapered roller bearing outer race.
Install tapered roller bearing outer races(2) with KM-304 (1) and KM-451 (3) in the
transmission and bearing race.
6. Fit axle shaft seal rings.
Install axle shaft seal rings with KM-446 in bearing race and transmission housing.
Transmission Case Assemble
Special Tools

KM-113-2 Bracket
KM-446 Installer Drift
KM-454-B Remover/Installer
KM-473 Sleeve
KM-552 Fixture
KM-982 Mount
KM-6037 Adapter
KM-6115 Bracket for Clutch Housing
KM-6155 Guide Pins
KM-6157 Assembly Sleeve
KM-6336 Installer
KM-6337 Installer
KM-6338 Installer
KM-6339 Installer
MKM-536-A Friction Coefficient Meter
1. Attach new transmission housing to KM-6115 .
2. Fit roller bearing(3) for main shaft.
Install roller bearing flush in transmission housing with KM-454-B -3(5) and KM-454-B -
4(4).
I mportant:Needle bearing side with writing points to transmission.
3. Fit needle bearing(2) for drive shaft.
Install needle bearing flush in transmission housing with KM-454-B -2(6) and KM-454-B -
4(1).

4. Insert differential into transmission from below.
I mportant:Align bearing race with marking previously made.
5. Install bearing race with KM-447 (2).
I mportant:The connection must be oil-tight.
6. Coat thread (arrow) and new O-ring(1) with multi-purpose grease.

7. Check clearance between tapered roller bearing and differential housing (external LU).
I mportant:Adjust bearing pre-tension by screwing in bearing race.
8. Check breakaway torque with MKM-536-A (1) and KM-6037 (2).
I mportant:Adhere to specified breakaway torques.
9. Test rpm 1revolution per second.
Breakaway Torque
60...100Ncm
Breakaway Torque
150...210Ncm
10. Clean thread for retaining plate bolt in transmission housing.
Noti ce: Refer to Fastener Notice in the Preface section.
I mportant:Insert bolt with locking compound.
11. Attach retaining plate for bearing ring.
12. Re-cut thread.
Tighten
Tighten bolt 9Nm (80lbin).
Re-use all the dismantled parts. Adjust to marking.
Re-use bearing, replacement of bearing race, bearing flange, differential or transmission
housing.
Bearing as new part

I mportant:Note seating and condition of the O-ring(2). Damage to or absence of the O-
ring leads to leaks.
13. Install fastening sleeve for pressure line(1). The lug (arrow) on the sleeve must sit in the
groove in the clutch housing.
14. Engage pressure line in fastening sleeve.

15. Clean 3x thread(1) in transmission.

16. Install central release(1).
Attach assembly aid MTA KM-6157 (3) to drive shaft(2), so that the seal ring (arrow) is
not damaged
Lightly coat seal ring in central release with transmission fluid.
Preassemble 3x bolt evenly in contact with the flange. Use new bolts.
I mportant:It is essential to avoid pulling the central release at an angle.
Tighten 3x bolt
Tighten
Tighten bolt to 5Nm (44lbin)

17. Attach pressure line(1).
Tighten
Tighten retaining nut 14Nm (10lbft).


18. Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using
transmission fluid.
19. Install bearing for main and drive shafts.

Press in 2x bearings using KM-523 -1(1) and KM-6336 (2)
Fit 2x retaining rings(3) -- check retaining ring for proper seating.

I mportant:Check shaft for proper seating.
20. Fit main and drive shafts.

Place main shaft(1) and drive shaft(4) on KM-6337 (5)
Place end shield(3) on main shaft and drive shaft and press on with KM-6338 (2)

21. Fit 5th gear bearing sleeve(1).

Locate end shield on KM-6337 (3)
Press bearing sleeve on main shaft using KM-6339 (2)

I mportant:Note installation position.
22. Fit reverse gear axle(1).

Locate reverse idler on axle -- note installation position, shift fork groove to top
Press reverse gear axle with inserted lock ball (arrow) to stop in end shield

23. Attach end shield to KM-552 (2) .
24. Attach end shield to KM-113-2 (1) using KM-552 (2) .

25. Fit locking pin(5). Insert 3rd/4th gear and reverse gear locking pins.
I mportant:To relieve pressure on gearshift rod guides in end shield, support gearshift rods
with wooden wedge(1) when securing with pin.
26. Fit reverse gear shift fork.

Insert reverse gear shift fork(6) and gearshift rod
Insert new roll pin using KM-308 (arrow) -- allow new roll pin to protrude approximately
2mm (0.08in)

with wooden wedge(2) when securing with pin.
27. Fit 1st/2nd gear shift fork.

Insert 1st/2nd gear shift fork(4) and gearshift rod(1)
Insert new roll pin using KM-308 (3) -- allow new roll pin to protrude approximately
2mm (0.08in)

28. Insert 5th gear(4) shift driver.
with wooden wedge when securing with pin.
29. Fit 3rd/4th gear shift fork.
30. Fit locking plugs.
Install 4x locking plugs (5-7) -- drive to stop with plastic hammer or soft metal drift.
31. Bring gear shift fork into neutral speed position.

Insert 3rd/4th gear shift fork(2) and gearshift rod(1)
Insert new roll pin using KM-308 (3) -- allow roll pin to protrude approximately 2mm
(0.08in)

32. Engage gear 3x.
33. Attach bridge(2) for locking bolt on end shield.
I mportant:Coat bolts with locking compound
34. Screw in 2x new bolt.
35. Move gearshift fork 1st/2nd gear into neutral.
36. Fasten 2x bolt for bridge.
Tighten
Tighten 2x bolt for bridge 7Nm (62lbft)
37. Bring shift fork into neutral position.
38. Attach bearing support(4) to end shield with pawl(3).
I mportant:Coat bolts with locking compound.
39. Tighten 2x bolt.
Tighten
Tighten 2x bolt 9Nm (80lbft).

Engage 2nd gear
Engage 3rd gear
Engage 5th gear

I mportant:Note installation direction. Long gear hub points to end shield.
40. Install 5th gear (driven)(2).
41. Fit 5th gear(5) (driven).

Insert end shield with main and drive shafts in KM-6337 (3)
Press on 5th gear using KM-473 (1)
I mportant:Retaining ring must engage completely.
fit new retaining ring
I mportant:Ensure correct seating of slotted needle bearings.
Coat needle bearings(6) with transmission fluid and place on main shaft
Locate 5th gear and 5th gear synchronizer ring on main shaft

42. Press on 5th gear synchro body assembly.
43. Fit bearing support with rocker arm.
Insert end shield in KM-6337
I mportant:Synchronizer ring lugs must be aligned with synchro body grooves.
Place synchro body assembly(1) on main shaft
Press synchro body in KM-473 on to main shaft
I mportant:Retaining ring must engage completely
fit new retaining ring
Insert 2x crosshead shoes (arrow) in 5th gear shift fork(3)
Insert bearing support with rocker arm in end shield
Insert 2x bolts with locking compound
Tighten 2x bolt
Tighten
Tighten 2x bolt 22Nm (16lbft)

44. Install friction washer and magnet.
Fit friction washer (arrow) on axle, reverse gear wheel, with grease
Insert magnet with grease
I mportant:Before installing end shield, check following items for position and
seating:
40.1. 3rd/4th gear shift fork
40.2. 3rd/4th gear shift rod
40.3. 5th gear shift driver
40.4. 1st/2nd gear shift rod
40.5. Lock pin for gear stop
40.6. 1st/2nd gear shift fork
45. Detach end shield from KM-113-2 . Detach end shield from KM-552 .

46. Attach KM-6155 to transmission.
47. Stick new end shield gasket to transmission with roller bearing grease.
I mportant:Check that magnet(1) and friction washer(2) are correctly seated.
48. Install end shield(4).
Tighten
Tighten 4x bolt (arrows) 22Nm (16lbft)
49. Unscrew KM-6155 (3).
40.7. Reverse gear shift fork
40.8. Reverse gear shift rod
Carefully insert end shield into transmission housing
Use new bolts

I mportant:Note close tolerance bolts.
50. Attach end shield cover.
Tighten
Tighten 4x bolt M7 15Nm (11lbft)
Tighten
Tighten 5x bolt M8 20Nm (15lbft)

Attach with new gasket to transmission housing
Tighten 4x bolt M7
Tighten 5x bolt M8

I mportant:Coat seal ring with grease.
51. Drive new seal ring with matching sleeve(1) flush into housing.
52. Push gearshift rod into gearbox cover and gearshift finger.
I mportant:Allow roll pin to protrude approximately 2mm (0.0787in)
53. Drive new roll pin into gearshift finger and gearshift rod.
I mportant:Gearshift finger must sit in gearbox intermediate lever.
54. Insert intermediate gearshift lever into gearbox cover.
55. Place washer(5), spring(4) and sleeve(3) on gearshift lever shaft.
Fit new retaining ring(2).

56. Attach gearbox cover to KM-982 .
I mportant:Guide bolt must sit in connecting link.
57. Drive guide bolt for connecting link(2) in gearbox cover.
I mportant:Do not damage engaging sleeve.
58. Drive engaging sleeve for intermediate shaft(1) with matching sleeve(3) into gearbox
cover.
59. Detach gearbox cover from KM-982 .

60. Attach gearbox cover(1) to transmission.
Tighten
Cement new gasket to transmission housing with grease
I mportant:Adjusting pin must sit in adjusting bore and lock the gearbox.
Place gearbox cover on transmission
Tighten 4x bolt
Tighten 4x bolt 15Nm (11lbft)

I mportant:Use new seal ring.
61. Fit reversing lamp switch(1).
Tighten reversing lamp switch(1).
Tighten
Tighten reversing lamp switch 20Nm (15lbft)

Draw adjusting pin(2) out of adjusting bore

62. Install new axle shaft seal ring.

63. Install left engine damping block.
Tighten
Tighten 3x bolt 55Nm (41lbft).
64. Detach transmission from KM-113-2 (1) using KM-6115 (2).
65. Detach transmission from KM-6115 .
Coat axle shaft seal ring with transmission fluid.
Install axle shaft seal ring flush in the transmission with KM-446 .

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2008 Saturn Astra | Astra (VIN A) Service Manual | Transmission/Transaxle | Manual Transmission - F17-5 |

Repair Instructions - Off Vehicle | Document I D: 2004044

If clearance is too small: No correction of clearance necessary because the gearshift

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