Dismantling and repair of the main gear and differential – Opel Kadett

Dismantling and repair of the main gear and differential

■ Unscrew the screws that attach the bottom cover of the main transmission to the gearbox housing and remove the cover.

■ If only the sealing rings in the housing are to be replaced, it is enough to pull them out with the appropriate welt.

■ Hitting the side cover of the main transmission bearing and the gearbox housing with the point, mark the position of the cover before removing it.

■ Move the differential housing in the post-axis direction with your hand to determine the clearance of tapered roller bearings. The same clearance must be maintained during the subsequent assembly of the main gear.

■ Unscrew the safety plate, and then unscrew the side bearing cover of the main gear (with the Opel-KM-447 special key). The differential housing must be held firmly when doing so. Take out the main gear with the differential through the hole in the unscrewed cover.

■ Pull out both sealing rings located in the side cover and in the gearbox housing with the appropriate tool. In the same way, remove the outer races of the tapered roller bearings.

■ Remove the internal raceways of both tapered roller bearings from the differential housing, using a puller with grasping legs.

■ Unscrew the bolts that secure the main gear driven wheel to the differential housing. Use a brass mallet to knock the wheel off the housing.

■ Use a cutter to disconnect the speedometer drive gear from the housing. During this operation, the wheel is destroyed. In the case of the F16 type gearbox, it is not necessary to remove the tapered roller bearings and the speedometer drive gear.

■ Remove the protection rings from both ends of the satellite axis (type F10) or remove the screw (type F16).

■ Knock the axis of the satellites out of the housing with the appropriate stem.

■ Remove satellites and crown wheels from the housing, and also thrust washers. Thoroughly clean all removed parts. Check the condition of the tapered roller and ball bearings. Press each bearing firmly between your hands in turn and rotate it in both directions. You should not feel any resistance. Damaged parts must be replaced.

Check the individual gears: the toothing may not be damaged or worn A wheel with damaged teeth should be replaced together with the mating gear. The axis of the satellites must be smooth over the entire surface Damage must also not show the seat of the axis in the satellites Minor unevenness can be removed with fine-grained sandpaper.