SECTION 7B2 - MANUAL TRANSMISSION -

V8 ENGINE

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). An SRS

will consist of either seat belt pre-tensioners and a driver's side air bag, or seat belt

pre-tensioners and a driver's and front passenger's side air bags. Refer to

CAUTIONS, Section 12M, before performing any service operation on or around any

SRS components, the steering mechanism or wiring. Failure to follow the CAUTIONS

could result in SRS deplo yment, resulting in possible p ersonal injury or unnecessary

SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas. In the interests of

safety, the LPG fuel system should be isolated by turning ‘OFF’ the manual service

valve and then draining the LPG serv ice lines, before any service w ork is carried out

on the vehicle. Refer to the LPG leaflet included with the Owner's Handbook for

details or LPG Section 2 for more specific servicing information.

CAUTION:

Whenever any component that forms part of the ABS or ABS/ETC (if fitted), is

disturbed during Service Operations, it is vital that the complete ABS or ABS/ETC

system is checked, using the procedure as detailed in 4. DIAGNOSIS, ABS or

ABS/ETC FUNCTION CHECK, in Section 12L ABS & A BS/ETC.

1. GENERAL INFORMATION

With the introduction of VT Series vehicles, the manual transmission fitted with the V8 engine, is the five speed,

Getrag, Type 290 (production option M34).

This manual transmission is optional equipment on V8 powered Executive models and Berlina.

The ‘290’ manual transmission is a fully synchronised unit, including reverse gear, with baulk ring type

synchronisers. The transmission primarily consists of a two piece transmission case, with the clutch housing

integrated with the front case section. During disassembly, the gear train and shift mechanism remain in the

transmission case rear section.

1.1 GENERAL DESCRIPTION

SYNCHRONISER ASSEMBLIES

Each of the three synchroniser hubs are splined to the mainshaft and secured either by selective snap rings to

accommodate manufacturing tolerances or by an interference fit, roller bearing sleeve. All synchromesh rings are

brass, with a molybdenum coating on the inner surface. Apart from Reverse gear, all sy nchromesh rings are the

same part. The purpose of the synchroniser assemblies is to permit clutching to the required gear, that is in

constant mesh with the cluster gear.

SYNCHRONISER ACTION

During synchroniser operation, the synchroniser sleeve is moved into engagement by the appropriate fork, carrying

with it three sy nchroniser inserts and spring loaded balls, located in slots in the synchroniser hub.

The synchroniser sleeve, together with the inserts, is moved along the hub, placing a load on the three lugs of the

blocking ring.

This initial force is sufficient to seat the blocking ring and start pre-synchronisation because of the friction between

the cone on the constant mesh gear and the blocking ring.

At this stage, gear engagement is prevented as long as there is a difference in speed between the mating surfaces

of the blocking ring and cone of the constant mesh gear. As the speeds between the blocking ring and the gear

cone become synchronised, the teeth on the blocking ring and gear cone line up with the internal splines of the

sleeve, allowing the sleeve to engage the teeth on the mainshaft gear, completing gear selection.

REVERSE GEAR

The reverse idler gear is in constant mesh with the cluster gear and the reverse gear that is mounted on the

mainshaft. When reverse gear is engaged, the 5th/reverse synchromesh sleeve engages the reverse constant

mesh gear, completing the selection.

BEARING SUPPORT

The maindrive gear runs on a single row ball race in the front of the transmission case and supports the front end of

the mainshaft via a caged needle roller bearing. The mainshaft runs on a single row ball race, mounted in the rear

transmission case .

The maindrive gear and mainshaft bearings are located in their respective housings by an interference fit and the

use of snap rings or a bolted plate. Shims are used to accommodate manufacturing tolerances in the front bearing

bore.

The cluster gear runs on two parallel roller bearings, one at each end, with end float being controlled by shim/s

located between the cluster gear front bearing cup and the front circlip.

Each of the mainshaft constant mesh gears run on caged needle roller bearings, while the reverse idler gear is

supported by two caged needle roller bearings running on the idler gear shaft.

LUBRICATION

Lubrication of all internal components is by splash feed, provided by the rotating cluster gear assembly.

SELECTOR MECHANISM

The floor mounted, gearshift control lever operates a single rail mechanism which extends into the rear

transmission case. The first/second, third/fourth and fifth/reverse shift forks are all supported at each end, in the two

transmission case s.

A shift interlock system, prevents engagement of more than one gear at a time. The system consists of an interlock

pin located in the third/fourth selector shaft and two interlock balls, that locate in a neutral position groove in each of

the remaining two shafts. These components, together with the shift detent balls and springs are all located in the

end of rear transmission housing.

When either the first/second or fifth/reverse selector shaft is moved to engage a gear, one of the interlock balls is

moved across, displacing the interlock pin, effectively locking the remaining two shafts. Moving the third/fourth

selector shaft, moves each of the two balls firmly into their respective shafts, allowing a third/fourth shift to take

place, with the interlock pin being carried with the shaft.

See Figure 7B2-1 for a sectioned view of the type ‘290’ transmission (production option M34). Figure 7B2-2 shows

an exploded view of the two case halves and selector components, while figure 7B2-3 shows an exploded view of

the gear train components.

1. Input Shaft

2. Maindrive Gear

3. Third Speed Gear

4. Second Speed Gear

5. First Speed Gear

6. Reverse Gear

7. Fifth Speed Gear

8. Mainshaft

9. Cluster Gear

Figure 7B2-1 - Type ‘290’ Transmission, Sectioned View

Figure 7B2-2 - Transmission Shift Mechanism and Case Components

REF

No. PART NAME REF

No. PART NAME

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

25.

26.

27.

27a.

28.

29.

30.

31.

Reverse blocker pin

Helical compression spring

Reverse blocker bushing, retainer

Reverse blocker bushing

Cap bolt

Cylindrical torsion spring

Reverse lock plate

Shift finger

Roll pin

Allen key head cap screw

Shift shaft support

Selector rod shift shaft

Dowel pin

Roller

Cylindrical torsion spring

Bushing

Select lever

Roller

Oil seal - shift shaft

Spring retaining clip

Selector rod trunnion pin

Selector rod trunnion

Detent ball - 3 places

Helical compression spring -

3 places

Cover plate

Bolt - 2 places

Wave washer - 2 places

Interlock ball - 2 places

Interlock ball plug - 2 places

Interlock pin

Propeller shaft sliding yoke bush

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

45a.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

Oil seal

Bolt - 3 places

Dowel pin - 2 places

Welsh plug

Magnet

Shift fork, 5th/Reverse

Roll pin

Selector shaft, 5th/Reverse

Shift fork, 3rd/4th

Selector shaft, 3rd/4th

Shift yoke, 1st/2nd

Shift fork, 1st/2nd

Selector shaft, 1st/2nd

Bolt

Wave washer

Front housing cover

Disc

O-ring

Clutch throwout bearing guide

Oil seal

Front transmission housing

Rear transmission housing

Helical compression spring

Plug

Drain plug

Back-up lamp switch

Detent plunger assembly

Helical compression spring

Plug

Filler plug

Reverse blocker pin bolt

Breather plug

Figure 7B2-3 - Transmission Gear Components

REF

No. PART NAME REF

No. PART NAME

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

Shim - selective

Selective snap ring

Spacer washer

Front bearing spacer ring

Front bearing

Input shaft and maindrive gear

Synchromesh ring

Caged, spigot needle roller bearing

Selective snap ring

Spacer washer

3rd/4th speed synchromesh hub

Spring

Ball

Sliding key

Synchromesh outer sleeve

3rd speed gear

Caged, needle roller bearing

Selective snap ring

Flanged needle roller bearing sleeve

2nd gear, needle roller bearing

2nd speed gear

1st/2nd speed synchromesh hub

Synchromesh outer sleeve

1st speed gear

1st speed, needle roller bearing

Mainshaft

Reverse gear, needle roller bearing

Reverse gear

Reverse synchromesh ring balls - 12

places

Synchromesh ring

5th/Reverse speed synchromesh

hub

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

52a.

53.

53a.

5th/Reverse speed synchromesh

outer sleeve

Selective snap ring

5th speed, needle roller bearing

5th speed gear

Rear mainshaft bearing retaining

plate

Rear mainshaft bearing assembly

Spacer washer

Selective snap ring

Circlip

Selective spacer washer

Cluster gear roller bearing cup -

2 places

Cluster gear needle roller bearing -

2 places

Cluster gear

Reverse idler gear

Reverse idler gear thrust washer

Reverse idler gear snap ring -

2 places

Caged needle roller bearings

Reverse idler gear shaft

Reverse idler gear thrust washer

locating ball

Reverse idler gear shaft front

support

Bolt

Wave washer

Bolt

Wave washer

1.2 POWER FLOWS

The maindrive gear, fifth, third, second, first speed and reverse gears are in constant mesh with the cluster gear.

Therefore, when the engine is running with the clutch engaged, torque is imparted to the maindrive gear and

through the cluster gear to the fifth, third, second, first speed and reverse gears at all times.

Refer to Figure 7B2-5 for illustrations relating to the following descriptions:

NEUTRAL

In neutral, with the clutch engaged, the maindrive gear turns the cluster gear. The cluster gear turns the constant

mesh gears because no synchroniser assemblies are engaged. As all constant mesh gears are supported on roller

bearings, they will also rotate with the cluster gear.

FIRST GEAR

In first gear, the first/second speed synchroniser sleeve is moved rearward to engage the first speed gear, which is

being turned by the cluster gear. Because the first/second speed synchroniser hub is splined to the mainshaft,

torque is imparted to the mainshaft from the first speed gear through the sy nchroniser sleeve and hub.

SECOND GEAR

In second gear, the first/second speed synchroniser sleeve is moved forward to engage the second speed gear,

which is being turned by the cluster gear. Because the first/second speed synchroniser hub is splined to the

mainshaft, torque is imparted to the mainshaft from the second speed gear through the synchroniser sleeve and

hub.

THIRD GEAR

In third gear, the first/second speed synchroniser sleeve assumes a neutral position. The third/fourth speed

synchroniser sleeve is moved rearward to engage the third speed gear, which is being turned by the cluster gear.

The engagement of the sleeve with the third speed gear, imparts torque to the mainshaft because the third/fourth

speed synchroniser hub is splined to the mainshaft.

FOURTH GEAR

In fourth gear, the third/fourth speed synchroniser sleeve is moved forward to engage the maindrive gear. This

engagement of the maindrive gear with the third/fourth synchroniser sleeve and hub assembly, imparts torque

directly to the mainshaft. While the cluster gear is still rotating, it does not impart torque to any component but

continues to lubricate the internal transmission components by the ‘splash’ method.

FIFTH GEAR

In fifth or overdrive gear, the first/second and third/fourth speed synchroniser sleeves assume neutral positions. The

fifth speed/reverse synchroniser sleeve is moved rearward to engage the fifth speed constant mesh gear, supported

on the mainshaft by a caged needle roller bearing. This engagement of the sleeve with the fifth speed constant

mesh gear, imparts torque from the cluster gear to the mainshaft, via the splined synchromesh hub.

REVERSE GEAR

In reverse gear, the fifth speed/reverse synchroniser sleeve is moved forward to engage the mainshaft reverse gear

and the cluster reverse gear, via the reverse idler gear. This imparts torque from the cluster reverse gear through

the idler gear (reversing direction of rotation) to the mainshaft reverse gear. Because the fifth speed/reverse

synchromesh hub is splined to the mainshaft, this causes the mainshaft to rotate in the opposite direction to the

maindrive gear.

MANUAL TRANSMISSION POWER FLOWS

Figure 7B2-5

1.3 TRANSMISSION SERIAL NUMBER

The transmission serial number is located on a

self-adhesive decal attached to the left side of the

transmission front housing.

This number provides coded information which

could be significant to parts interpretation and

should be referred to when ordering replacement

parts.

Figure 7B2-4

2. SERVICI NG I NFORMATION

2.1 RECOMMENDED LUBRICANT

The recommended lubricant for the ‘290’ manual transmission is an 80W gear oil to Holden’s Specification HN1855,

such as Castrol VMX80W or equivalent.

The transmission lubricant capacity is approximately 1.8 litres.

2.2 CHECKING TRANSMISSION LUBRICANT LEVEL

To check transmission lubricant level, remove

transmission filler plug (1), using a commercially

available, 17 mm Allen key socket, f rom right hand

side of transmission case.

The level is correct when lubricant is level with the

filler plug threads.

NOTE:

Ensure that the vehicle is on level ground and

transmission is cold.

If necessary, add lubricant to bring to the correct

level.

Reinstall filler plug and tighten to the correc t torque

specif ic ation. Do not apply thread sealant or tape to

the plug threads.

TRANSMISSION FILLER PLUG 25

TORQUE SPECIFICATION Nm

Lubricant level is to be checked at the time or

distance intervals detailed in the VT Ser ies Owner's

Handbook.

Figure 7B2-6

2.3 DRAINING AND REFILLING TRANSMISSION

While the initial fill of transmission lubricant is

specif ied as a ‘fill for lif e’, s hould a lubr icant c hange

be required, then the following procedure should be

adopted.

1. To drain transmission, jack up vehicle front

and rear and support on safety stands.

Refer to Section 0A GENERAL

INFORMATION for the location of jacking

points.

2. Place a drain tray beneath transmission and

remove filler plug and then drain plug (‘2’ in

Figure 7B2-6) using a using a commercially

available, 17 mm Allen key socket.

3. When transmission has fully drained, insert

drain plug (2) and tighten to the correct torque

specification. Do not apply thread sealant or

tape to the plug threads.

TRANSMISSION DRAIN PLUG

TORQUE SPECIFICATION 40 - 60

4. Refill transmission to correct level, refer to

2.2 CHECKING TRANSMISSION

LUBRICANT LEVEL in this Section.

3. MI NOR SERVICE OPERATIONS

3.1 BACK-UP LAMP SW ITCH

REMOVE

1. Raise front of vehicle and support on safety

stands.

Refer to Section 0A GENERAL

INFORMATION for the location of jacking

points.

2. Remove wiring harness connector from

switch, located on the right hand side of the

transmission case.

3. Loosen, then remove switch from the

transmission case.

Figure 7B2-7

REINSTALL

1. Ensure that the switch threads are clean.

2. Install switch (arrow) to transmission case and

tighten to the correct torque specification.

BACK-UP LAMP SWITCH 20

TORQUE SPECIFICATION Nm

3. Install wiring harness connector to switch.

4. Remove safety stands and lower vehicle to

ground.

5. Check back-up lamp operation.

Figure 7B2-8

Techline

3.2 SPEED SENSOR AND/OR BRACKET

REPLACE

1. Jack up vehicle front and rear and support on

safety stands. Refer to Sect ion 0A GENERAL

INFORMATION for the location of jacking

points.

2. Remove the speed sensor wiring harness

connector from the mounting clip (2), fitted to

the transmission shift brace bracket.

3. Disconnect speed sensor wiring harness

connector (3 and 4).

Figure 7B2-9

4. Remove speed sensor mounting bracket nut

(2) from the rear transmission housing.

5. Remove the bracket and sensor assembly

from the rear transmission housing.

6. Remove the sensor to brack et retaining screw

(1), then disconnect the sensor by a twisting

and pulling motion to free the O-ring s eal from

the bracket.

7. Installation is the reverse of removal except for

the following points;

a. Tighten the speed sensor to mounting

bracket retaining screw (1) to the correct

torque specification.

SPEED SENSOR TO BRACKET 6 - 14

SCREW TORQUE SPECIFICATION Nm

b. Install the speed sensor mounting brac ket

to the lug on the transmission case,

aligning the locating pin with the hole.

Tighten the sensor bracket to

transmission housing mounting nut (2) to

the correct torque specification.

SPEED SENSOR BRACKET TO

TRANSMISSION HOUSING BOLT 15 - 20 Nm

TORQUE SPECIFICATION

c. Connect the speed sens or lead connec tor

to the transmission wiring harness

connector, then ins tall to the c lip ( 3), fitted

to the transmission shift brace bracket.

Figure 7B2-10

3.3 GEARSHIFT LEVER KNOB AND BOOT ASSEMBLY

NOTE:

The gearshift lever knob and console boot are

manufactured as a single component. Do not

attempt to remove the gearshift lever knob

separately to the boot.

REMOVE

1. With the fingers of one hand hooked under the

edge of the gearshift lever boot as shown,

caref ully release each of the 8 plas tic retainer s

and free the gearshift lever boot from the

console cap.

Figure 7B2-11

2. Lift the gears hif t lever boot enough to enable a

firm grasp to be made on the gearshift lever

with the left hand, then grasp the gearshift

knob with the right.

3. W hile rocking the knob sideways, and with an

upward force applied, dislodge the knob

retaining claws from the lever.

4. Remove the gearshift lever knob and boot

assembly, from the gearshift lever.

Figure 7B2-12

REINSTALL

1. Reinstall the knob and boot as sem bly over the

gearshift lever, align the knob in the correct

attitude and then bump the knob onto the

gearshif t lever until the retaining claws engage

with the groove in the lever.

2. Align the boot retaining clips with the hole in

the console cap, then carefully seat the boot

retainers into the console cap until each clip

engages correctly.

3.4 GEARSHIFT LEVER

REMOVE

1. Remove the gearshift lever knob and boot

assembly, from the gearshift lever. Refer to

3.3 GEARSHIFT LEVER KNOB AND BOOT

ASSEMBLY in this Section, for the necessary

procedure.

2. Raise vehicle front and rear and support on

safety stands. Refer to Section 0A

GENERAL INFORMATION for the location of

jacking points.

3. Scribe around each of the rear engine

mounting crossmember mounting points

(arrows) to the vehicle underbody, to provide

an alignment reference for reassembly.

Also scribe around the rear mounting nut

washers, marking their location on the alloy

crossmember.

IMPORTANT:

These steps are critical to the correct powertrain

alignment on reassembly. If not carried out, then

vehicle vibration and/or handling problems will

result!

4. Support the rear of the transmission with a

floor jack, then remove the four rear engine

mounting crossmember bolts.

Figure 7B2-13

5. Lower the rear of the transmission, sufficient

to gain access to the front end of the shift

linkage brace (2).

6. From under vehicle, prise the shift linkage

brace retainer (1) loose, at the transmission

end, using a screwdriver or suitable lever.

7. Remove the retainer and pin from the

transmission case bracket.

Figure 7B2-14

8. Remove the four gearshift lever bracket,

mounting nuts (arrows) from inside the

vehicle.

Figure 7B2-15

9. Remove the retaining C-clip (1) and washer

(2) from the transmission shift rod coupling

(4), at the gearshift lever end.

10. Remove two gearshift lever support mounting

bolts (5) from underfloor bracket.

11. Remove gearshift lever assembly, with rubber

boot and the complete brace assembly, from

below the vehicle.

NOTE 1:

If the shift rod (4) is disconnected from the

transmission end and removed from the vehicle

with the brace assem bly, take particular note of the

rod’s orientation for correct installation. Take care

not to lose the washer on the inner end of the rod.

NOTE 2:

W hile the illustration shows the propeller shaft and

exhaust removed for clarity, removal of the brace

assembly from the vehicle, is possible without first

removing these items. Figure 7B2-16

DISASSEMBLE

1. Remove both nuts (1) securing the gearshift

lever ball socket retainer, to the mounting

brace.

2. Remove retainer and gearshift lever assem bly

from the brace.

Figure 7B2-17

3. Remove the boot and mounting bracket

assembly (4) from the gearshift lever (2).

4. Separate the assem bly by holding the bearing

cover (5), and gently bump the end of the

gearshift lever (2), to displace the end plate

(6), spacer plate (7) and bearing (1) from the

ball of the gearshift lever.

5. Inspect all components for wear and/or

damage, replacing as required.

Figure 7B2-18

REASSEMBLE

Reassembly operations are the reverse of

disassembly, except for the following items.

1. Lubricate the gearshift lever ball and socket

with Lithium grease NLGI No. 4 EP.

2. Install the gearshift lever ball and socket

retainer to the brace, fit the two retaining nuts

(1) but do not tighten at this time.

GEARSHIFT BALL SOCKET

RETAINER PLATE NUTS 6 - 14 Nm

TORQUE SPECIFICATION

Figure 7B2-19

3. Install the rubber gearshift boot and plate

assembly over the gearshift lever as shown.

Figure 7B2-20

REINSTALL

1. Install gearshift lever assembly into position,

aligning studs with the holes in the floor pan

and the bolt holes in the rubber m ounting, with

the captive nuts on the underbody.

2. Install gearshift lever brace rubber mounting

bolts (2) and tighten to the correct torque

specification.

SHIFT LEVER BRACE, RUBBER

MOUNTING BRACKET BOLT 6 - 14 Nm

TORQUE SPECIFICATION

3. From inside the vehicle, install and tighten the

four, brace (1) to underfloor retaining nuts,

tightening to the correct torque specification.

SHIFT LEVER BRACE TO

UNDERFLOOR RETAINING NUT 6 - 14 Nm

TORQUE SPECIFICATION

Figure 7B2-21

4. Install gearshift brace pin and retainer (1) to

the transmission bracket , ensuring that the

security lug is firmly in place.

Figure 7B2-22

5. Install gearsh ift linkage to the lower end of the

gearshift lever, then install the washer (2) and

C-clip (1).

NOTE:

Ensure that the linkage is only assembled in the

attitude shown. If fitted in the reverse direction, the

linkage may foul, resulting in diffic ulty with 2nd gear

selection that can cause damage to the

transmission.

Figure 7B2-23

ADJUST

1. Place gearshift selector in first gear.

2. Adjust knob position to achieve a 75 ± 5 mm

clearance to the closest part of the radio facia.

3. Tighten gearshift ball socket nuts (3) to the

correct torque specification, refer Fig. 7B2-23.

GEARSHIFT BALL SOCKET

RETAINER PLATE NUTS 6-14 Nm

TORQUE SPECIFICATION

4. Check that the gears hift lever does not c ontact

the console cap when 2n

, 4

and Reverse

gears are selected.

5. Re-check that the gearshift knob to radio

clearance is correct.

6. Remove safety stands and lower vehicle to

ground.

7. Reinstall gearshift lever knob/boot assembly.

Refer to 3.3 GEARSHIFT LEVER KNOB AND

BOOT ASSEMBLY in this Section, for details.

8. Road test vehicle to check gearshift operation.

3.5 SHIFT LINKAGE BRACE RUBBER MOUNTING AND/OR BUSH

REPLACE

1. Remove the gearshift lever and brace

assembly from the vehicle, as detailed in

3.4 GEARSHIFT LEVER in this Section.

Brace Mounting

2. Remove the rubber mounting from the rear of

the gearshift lever support after removing the

retaining nut (1).

3. Fit the rear mounting to the brace, inserting

the locating tang (2) in the hole provided.

Install the retaining nut (1) and tighten to the

correct torque specification.

REAR GEARSHIFT LINKAGE

RUBBER MOUNTING NUT 22 Nm

TORQUE SPECIFICATION

Figure 7B2-24

BRACE BUSH

4. Using a suitable sized pin punch and ham m er,

remove the rubber bushing from the

transmission end of the brace assembly,

clamping the eye of the brace between

protected vice jaws.

Figure 7B2-25

5. Using a suitable sized piece of tubing (or

sock et) , over the end of the brac e eye, use the

clamping effect of a bench vice to install the

replacement rubber bush.

NOTE:

Dip the replacement bushing in a soap solution to

assist in the installation process.

6. Reinstall the brace and gearshift assembly into

the vehicle, as detailed in

3.4 GEARSHIFT LEVER, in this Section.

Figure 7B2-26

4. MAJOR SERVICE OPERATIONS

4.1 TRANSMISSION CASE REAR SEAL

REMOVE

1. Disconnect battery earth lead.

2. Raise front and rear of vehicle, supporting on

safety stands. Refer to Section 0A

GENERAL INFORMATION for the location of

jacking points.

3. Support weight of transm ission as sembly on a

transmission jack.

4. Use a sharp s criber to m ark the exac t location

of the crossmember to the side frame

(arrows), before loosening any of the four

crossmember to side frame attaching bolts.

Also scribe around the rear mounting nut

washers, marking their location on the alloy

crossmember.

IMPORTANT:

These steps are critical to the correct powertrain

alignment on reassembly. If not carried out, then

vehicle vibration and/or handling problems will

result!

Figure 7B2-27

5. Remove engine rear crossmember to side

frame attaching bolts (3) and spacer blocks

(1).

6. Remove crossmember to rear mounting

attaching nuts (4), then remove crossmember

(2) from the vehicle.

NOTE:

Illustration does not show transmission jack in

position, for clarity of the crossmember orientation.

Figure 7B2-28

Remove the speed sensor mounting bracket bolt

and nut (2) from the rear of the transmission, then

disconnect the wiring harnes s c onnec tor s ec ured to

the end bracket (3).

Remove the sensor and bracket from the vehicle

and secure to the vehic le underbody, us ing tie wire

or similar.

Figure 7B2-29

8. Remove centre bearing carrier to underbody

reinforcement bolts and spacers.

NOTE:

For correct reassembly, take particular note of any

spacer arrangement that may be fitted, observing

any side to side variations and the orientation of the

bracket offset.

9. Support centre bearing assembly to prevent

any angular deflection of the constant velocity

joint that exceeds 8°. Should this angle be

exceeded, then damage to the boot and/or

constant velocity joint may occur.

Figure 7B2-30

10. Place a drain tray beneath transmission.

11. Remove bolts and nuts holding propeller shaft

rear universal joint flange to pinion flange.

Disengage rear universal joint flange from

pinion flange.

NOTE:

The two flanges have paint alignment marks that

are assem bled as c lose together as pos sible. If the

marks are not visible, scribe a mark on both

flanges so that they may be reinstalled in their

correct position.

12. Disconnect the propeller shaft from the rear

flange and, moving the propeller shaft slightly

to the left hand side of the vehicle, pull the

assembly toward the rear of vehicle, sufficient

to disengage the slip joint from the

transmission mainshaft. Figure 7B2-31

13. Using a seal rem over such as Tool No. E308,

remove the seal from the transmission case.

NOTE:

Should Tool No. E308 not be available, then it will

be necessary to use a small, sharp cold chisel and

hamm er to pierce the seal. T hen, use the chisel as

a lever to remove the seal from the transmission

case.

Figure 7B2-32

SPEED SENSOR TOOTHED RING - REPLACE

During intial assembly, the toothed ring is pressed

onto the slip yoke and then swaged for security.

Therefore, as these parts are not serviced

separately, the assembly must be fitted, if

replacement of either component is required.

REINSTALL

1. After lubricating the seal lip with transmission

lubricant, lightly smear Loctite 574 sealant (or

equivalent, to Holden’s Specification HN2216)

around the outer seal surface.

Use previously released Tool No. J-21426 (or

similar) and install the new seal into the rear

transmission case .

Install the propeller slip joint into the rear of the

transmission, then lift the propeller shaft upward

(while maintaining and angular deflection less than

8°) and install centre bearing carrier to underbody

reinforcement. Ensure all spacers are replaced in

the same positions, noted on removal, then install

retaining bolts.

Assem ble propeller shaft rear universal joint flange

to pinion flange and install attaching bolts and nuts.

Figure 7B2-33

5. Tighten all propeller shaft attaching bolts to the

correct torque specification.

CENTRE BEARING CARRIER TO

UNDERBODY REINFORCEMENT 20 - 25 Nm

BOLT, TORQUE SPECIFICATION

PROPELLER SHAFT REAR

UNIVERSAL JOINT FLANGE TO 55 - 65

PINION FLANGE BOLT Nm

TORQUE SPECIFICATION

6. Reinstall speed sensor and bracket assembly

to the casting flange on the rear transmission

housing, tightening the retaining nut (2) to the

correct torque specification.

SPEED SENSOR RETAINING 15 - 20

NUT TORQUE SPECIFICATION Nm

Figure 7B2-34

7. After noting the orientation of the rear

crossmember, relative to the installed

transmission, install the rear crossmember to

the rear mounting, loosely installing attaching

nuts.

Figure 7B2-35

8. Loosely install rear crossmember to side

fram e mem ber bolts (3), inc luding the spacers

(1).

9. Carefully align the scribed marks made prior to

rem oval, then tighten the four cr ossm ember to

side frame bolts (3) to the correct torque

specification.

REAR CROSSMEMBER TO SIDE

FRAME MEMBER BOLT 50 - 65 Nm

TORQUE SPECIFICATION

IMPORTANT:

This step is critical to the correct powertrain

alignment. If not carried out, then vehicle vibration

and/or handling problems will result!

10. Remove transmission jack.

11. After checking to see that the crossmember

position has not changed, tighten the rear

mounting nuts (4) to the correct torque

specification.

REAR CROSSMEMBER TO REAR

MOUNTING ATTACHING NUT 20 - 30 Nm

TORQUE SPECIFICATION

12. Check transmission lubricant level and top up

as necessary, refer 2.2, CHECKING

TRANSMISSION LUBRICANT LEVEL in this

Section.

Figure 7B2-36

13. Remove jack stands and lower vehicle to the

ground.

14. Reconnect battery ground lead.

15. Road test vehicle to check the gearshift

operation.

4.2 TRANSMISSION ASSEMBLY

REMOVE

1. Disconnect battery ground lead.

2. Raise vehicle front and rear and support on

safety stands. Refer to Sect ion 0A GENERAL

INFORMATION for the location of jacking

points.

3. Disconnect wiring harness connectors from

each of the two oxygen sensors (1).

NOTE:

While an automatic transmission equipped view is

shown, the location of the oxygen sensors for the

manual transmission equipped vehicles is identical.

Figure 7B2-37

4. Depending on the reason for rem oval, it might

be opportune to drain the transmission

lubricant into a clean container.

Place a drain tray beneath transmission and

rem ove filler plug and then drain plug ( 2) us ing

a commercially available, 17 mm Allen key

socket.

When transmission has fully drained, insert

drain plug (2) and tighten to the c orrect torque

specification.

TRANSMISSION DRAIN PLUG 40 - 60

TORQUE SPECIFICATION Nm

Figure 7B2-38

5. Support weight of transm ission as sembly on a

transmission jack.

6. Use a sharp s criber to m ark the exac t location

of the crossmember to the side frame

(arrows), before loosening any of the four

crossmember to side frame attaching bolts.

IMPORTANT:

This step is critical to the correct powertrain

alignment on reassembly. If not carried out, then

vehicle vibration and/or handling problems will

result!

Figure 7B2-39

Techline

7. Remove engine rear crossmember to side

frame attaching bolts (3) and spacers (1).

8. Remove crossmember to rear mounting

attaching nuts (4), then remove the

crossmember (2) from the vehicle.

NOTE:

Illustration does not show transmission jack in

position, for clarity of the crossmember orientation.

Figure 7B2-40

10. Remove centre bearing carrier to underbody

reinforcement bolts and spacers.

NOTE 1:

For correct reassembly, take particular note of any

spacer arrangement that may be fitted, observing

any side to side variations and the orientation of the

bracket offset.

NOTE 2:

Support centre bearing assembly to prevent any

angular deflection of the constant velocity joint that

exceeds 8°. Should this angle be exceeded, then

damage to the boot and/or constant velocity joint

may occur. Figure 7B2-41

11. Place a drain tray beneath transmission.

12. Remove bolts and nuts holding propeller shaft

rear universal joint flange to pinion flange.

Discard the crimped nuts.

Disengage rear universal joint flange from

pinion flange.

NOTE:

The two flanges have paint alignment marks that

are assembled as close together as possible.

If the marks are not visible, scribe a mark on both

flanges so that they may be reinstalled in their

correct position.

13. Disconnect the propeller shaft from the rear

flange and, moving the propeller shaft slightly

to the left hand side of the vehicle, pull the

assembly toward the rear of vehicle, sufficient

to disengage the slip joint from the

transmission mainshaft. Figure 7B2-42

14. Disconnect the speed sensor wiring harness

connector (1 and 3) secured in a clip (2),

attached to the bracket bolted to the rear of

the transmission. Connector (4) is for the left

hand oxygen sensor.

Figure 7B2-43

15. Disconnect wiring harness connector from

back up lamp switch.

Figure 7B2-44

16. Remove clutch actuating cylinder retaining

nuts (arrows), remove the cylinder from the

transmission and secure to one side with tie

wire or similar.

Figure 7B2-45

17. Remove the starter motor. Refer to

Section 6D2-2, STARTING SYSTEM - V8

ENGINE, for the necessary procedures.

18. Remove four screws (1) securing the lower

flywheel cover plate (2) to the transmission

clutch housing.

19. Lower transmission slowly on jack, still

supporting weight of transmission.

Figure 7B2-46

20. Disconnect wiring harness from the retaining

clips; one on top of the transmission case (4),

the right hand side (2) and from the gearshift

brace braket (See Figure 7B2-47).

Figure 7B2-47

21. Using a screwdriver, remove retainer (4) from

shift rod (3) at the transmission end. Remove

the shift rod (3) from the selector rod trunnion

(5).

22. Using a suitable lever, prise the shift linkage

brace retainer (1) from the transmission

bracket, then remove retainer and pin

assembly from brace (2) and transmission

bracket.

Figure 7B2-48

23. Remove the six transmission case to engine

block attaching bolts.

24. Withdraw transmission from the engine block

and clutch driven plate.

NOTE 1:

Keep the transmission assembly supported so that

it does not tilt in relation to the engine, until the

maindrive gear splines are clear of the clutch driven

plate. If the transmission is allowed to hang on the

splines, the clutch driven plate will be damaged.

IMPORTANT:

As the transmission is drawn rearward, take

particular care not to damage the two oxygen

sensors in each exhaust pipe.

Figure 7B2-49

REINSTALL

1. Put transmission into 4th gear.

2. Apply a thin coating of Special High

Tem per ature grease ( to Holden's Spec ification

HN1227) to maindrive gear splines. Push the

clutch throwout bearing into the fully released

position (arrow), ensuring that placement with

the throwout fork, is correct.

3. Raise transmission on jack and install

maindrive gear into splines of clutch driven

plate and push transmission toward engine

block. It may be necessary to rotate the

mainshaft after temporarily installing the

propeller shaft, to assist in spline alignment.

4. Install flywheel lower cover plate before

pushing the transmission fully home on to the

guide pins, then install the four retaining

screws tightening to the correct torque

specification.

FLYWHEEL LOWER COVER PLATE 5 - 10

SCREW TORQUE SPECIFICATION Nm

5. Install and tighten the six clutch housing to

engine block attaching bolts, tightening to the

correct torque specification. Note that the top

right bolt also has a wiring harness mounting

clip under the head.

CLUTCH HOUSING TO ENGINE

BLOCK BOLT 30 - 45 Nm

TORQUE SPECIFICATION

6. Using transmission jack, support transmission

in a lower than installed position.

Figure 7B2-50

7. Install wiring harness into retaining clips (2 and

4).

Figure 7B2-51

8. Align the shift linkage brace (2) and the

transmission brace, lug holes. Install the pin

from the left hand side, then rotate, to engage

the retaining clip (1) with the bracket. Tap to

fully engage the clip with the bracket.

9. Raise the transmission assembly into the

installed position.

10. Fit a washer to the inner end of the shift

linkage pin (3), apply a small amount of

Molybdenum Disulphide grease (Holden’s

Specification HN1461) to the pin, then install

into the transmission shift rod trunnion (5).

Install a second washer to the shift linkage pin,

then secure with the retaining clip (4).

11. Reinstall wiring harness connector to back up

lamp switch and to the speed sensor.

12. Reinstall propeller shaft slip joint into the

transm ission mains haft, supporting the centre,

constant velocity joint at an angle not

exceeding 8°, to avoid damage to the joint

and/or boot.

13. Lift propeller shaft upward and install centre

bearing carrier to underbody reinforcement,

ensuring that all spacers are replaced in the

same positions, noted on removal. Install

retaining bolts.

Figure 7B2-52

14. Assemble propeller shaft rear universal joint

flange to pinion flange and install attaching

bolts and nuts.

15. Tighten all propeller shaft attaching bolts to

the correct torque specification.

CENTRE BEARING CARRIER TO

UNDERBODY REINFORCEMENT 20 - 35 Nm

BOLT TORQUE SPECIFICATION

PROPELLER SHAFT REAR

UNIVERSAL JOINT FLANGE BOLT 55 - 65 Nm

TORQUE SPECIFICATION

16. Install clutch actuating cylinder to transm ission

case, install the nuts and tighten to the correc t

torque specification.

CLUTCH ACTUATING CYLINDER

RETAINING NUT 22 Nm

TORQUE SPECIFICATION

NOTE:

When the slave cylinder is engaged with the

mounting studs, the internal spring will hold the

flange out from the fully installed position, by

approximately 25 mm. Hold the cylinder in against

this spring force, to start the retaining nuts.

17. Install rear crossmember to rear mounting,

install washers and attaching nuts.

18. After noting the orientation of the rear

crossmember, relative to the installed

transmission, install the rear crossmember to

the rear mounting, loosely installing attaching

nuts.

Figure 7B2-53

19. Loosely install rear crossmember to side

fram e mem ber bolts (3), inc luding the spacers

(1).

20. Carefully align the scribed marks made prior to

rem oval, then tighten the four cr ossm ember to

side frame bolts (3) to the correct torque

specification.

REAR CROSSMEMBER TO SIDE

FRAME MEMBER BOLT 50 - 65 Nm

TORQUE SPECIFICATION

IMPORTANT:

This step is critical to the correct powertrain

alignment. If not carried out, then vehicle vibration

and/or handling problems will result!

21. Remove transmission jack.

22. After checking to see that the crossmember

position has not changed, tighten the rear

mounting nuts (4) to the correct torque

specification.

REAR CROSSMEMBER TO REAR

MOUNTING ATTACHING NUT 20 - 30 Nm

TORQUE SPECIFICATION

23. If transmission fluid was drained during the

removal operation, then refill, as described in

2.3 DRAINING AND REFILLING

TRANSMISSION, in this Section.

24. Remove safety stands and lower vehicle.

25. Reconnect battery earth lead.

26. Road test vehicle and check transmission,

clutch and gearshift operations.

Figure 7B2-54

4.3 TRANSMISSION DISASSEMBLE

1. Remove the bolt (2) securing the engine

mount (1) and adaptor plate to the underside

of the rear transmission case and set the

mounting and plate to one side.

Figure 7B2-55

2. If not carried out during the transmission

removal procedure, use a commercially

available, 17 mm Allen key socket, remove

transm iss ion filler plug ( 1) f rom right hand side

of transmission case.

3. Remove transmission drain plug (2) with the

same Allen key socket and allow transmission

lubricant to drain into a suitable clean, drain

tray of at least 1.5 litre capacity.

Figure 7B2-56

4. Release clutch releas e lever from the wire clip

(1) and remove lever (2) from transmission

case, together with the thrust bearing (3).

Figure 7B2-57

5. Remove bolts attaching throwout bearing

guide assembly. Gently tap sideways with a

soft faced hammer to break the seal, then

remove the assembly from the transmission

maindrive gear shaft.

Figure 7B2-58

6. I fitted, rem ove shim washer ( 2) from the front

bearing spacer (4). Using suitable snap ring

pliers (1) , r emove the snap r ing (3) and s pacer

washer from maindrive gear.

Figure 7B2-59

7. Remove the two bolts (2) securing the

gearshift brace bracket (1) to the rear of the

transmission case and set the brace to one

side.

Figure 7B2-60

8. Lever the spring steel retaining ring forward

from selector rod trunnion, to expose the

connecting pin.

While pushing the trunnion in to the

transmission, use a suitable punch and push

the pin from the trunnion. Remove trunnion

and retaining ring from the selector rod.

Figure 7B2-61

9. Remove back-up lamp switch.

Figure 7B2-62

12. Using suitable lever, remove detent plug (3)

from front section of transmission case.

13. Remove detent pin (1), pressure spring (2)

and plug (3).

Figure 7B2-63

14. Drive both locating dowel pins (2) into the f r ont

transmission case .

15. Remove transmission case attaching bolts

from case rear section. Take note of the

location of the 5 longer bolts (3) for

reassembly.

Figure 7B2-64

16. Install extractor, Tool No. AKM-628-A, to front

of transm ission case using all six of the clutch

throwout bearing guide bolts (1).

17. Tighten extractor forcing bolt to separate

transmission case sections.

NOTE:

While the forcing bolt of Tool AKM-628-A has

torque applied, it may be necessary to use a

suitable soft faced hammer and tap the sealed join

between the tow transmission cases, to assist in

the separation process.

18. Carefully remove the front transmission case

section and place to one side.

IMPORTANT:

After the tr ansmission c ases have been separated,

do not lift or move the transmission rear section by

using the maindrive gear as a lever or handle. If

this is done, then the mainshaft spigot bearing will

suffer brinelling and be permanently damaged.

NOTE:

The maindrive gear bearing and cluster gear front

bearing cup remain in the transmission case front

section. Take care that the cluster gear roller

bearing does not fall out of the front case

immediately after splitting the cases. The

remainder of the transmission assembly is

removed with the transmission case rear section.

Figure 7B2-65

19. Remove expansion plug (2) from the rear

transmission c ase, by tapping on one side with

a pin punch and hammer to turn the plug

sideways, then remove with a suitable pair of

pliers.

20. Using a 3/8” drive, 13 m m socket, remove the

two reverse idler shaft bolts; one located under

the expansion plug (1) , the other at the f r ont of

the rear transmission case (3), as shown.

Figure 7B2-66

21. Remove the idler gear shaft, front support (2)

by rotating it around the reverse idler shaft,

then remove the reverse idler s haf t and needle

roller assembly (1) from the transmission

case.

NOTE:

Remo val of the revers e idler gear is not possible at

this stage.

Figure 7B2-67

22. Select 4th gear to position the shift selector

rod as far forward as possible.

Support the shift selector rod (3) with a

wooden wedge (4) as shown, then remove the

roll pin from the gearshift selector arm (1),

using a suitable sized pin punch (2). Take care

not to drive the pin into the gear teeth below.

Figure 7B2-68

23. Using a soft faced hammer, tap the shift rod

(1) rearwards through the bearing support,

removing the seal (2) in the same operation.

NOTE:

As the shift rod is removed, there are four rollers

(3) that can be dislodged from the pins in the s haft.

Take care not to lose them.

Figure 7B2-69

24. Remove the locking lever screw plug and

spring guide (2) from the rear transmission

case, using a 19 m m r ing spanner, noting that

sealant is applied to the plug threads.

CAUTION:

As the plug has spr ing force applied, tak e c are that

the plug does not fly out when unscrewed.

25. Remove the spring (1) from the transmission

case.

Figure 7B2-70

26. Remove bolts attaching detent cover plate to

transmission case rear section. Remove the

plate (1) and three equal length, detent springs

(2).

Figure 7B2-71

27. Using a pencil magnet, remove three detent

balls (1) from under the springs, two interlock

plugs (2) and two interlock balls (3 ) f r om under

the plugs.

NOTE:

Unless the two interlock balls (3) are rem oved from

under the interlock plugs, the disassembly

procedure that follows, will be invalid.

Figure 7B2-72

28. Install loading Tool No. AU462. Firs t, ins er t the

shaft (1) from the rear into the selector arm

(2), engaging the lugs with the selector arm.

Install the sleeve of Tool AU462 over the

protruding shaft (1) on the geartrain side.

29. Use a scr ewdriver to lif t the end of the s elec tor

shaft spring (5), allowing the leg of the loading

tool sleeve to engage with the spring end.

30. Rotate the loading tool sleeve counter-

clockwise, tensioning the selector arm spring,

then lock the assembly to maintain the spring

in a tensioned state, by tightening the locking

screw (3).

NOTE:

The assembly is shown in the removed state to

more clearly show the arrangement.

Figure 7B2-73

31. Using a 6 mm Allen key (or socket), remove

the gearshift selector rod bush lock bolt from

the rear transmission case.

NOTE:

The loc k bolt has sealant applied to the thread and

will be diffic ult to rem ove unless a hot air gun is not

used to soften the sealant, prior to removal.

32. Carefully remove the tensioned ass em bly from

the rear transm iss ion cas e sec tion, taking care

not to lose the roller from the selector arm pin.

Figure 7B2-74

33. Using a 6 mm Allen key (or socket), remove

the three bolts (arrows) securing the rear

mainshaft bearing retaining plate. Note that

sealant is also applied to the bolt threads.

Figure 7B2-75

34. To remove mainshaft and cluster gear

assemblies, together with the selector shafts

and forks from rear transmission case,

support the mainshaft on a suitable block of

wood, in a vertical position as shown.

35. Using a plastic faced hammer, remove the

rear case section from the rear mainshaft

bearing.

NOTE:

During this removal operation, check that the

interlock pin fitted to the 3rd/4th selec tor s haft does

not slip sideways and jam the shaft in its bore.

Should this occur and remain unnoticed, then

removal of the rear case will not be possible or it

will be damaged by the dislodged interlock pin.

Figure 7B2-76

36. Once free, the cluster gear assem bly, reverse

idler gear and selector rails and forks can be

easily separated from the mainshaft assembly.

Figure 7B2-77

4.4 TRANSMISSION SUB-ASSEMBLIES

DISASSEMBLE

MAINSHAFT

1. Remove maindrive gear and fourth speed gear

synchromesh ring from mainshaft.

Remove 3rd/4th gear synchromesh assembly

(3) selective snap ring (2) from front end of

mainshaft, using suitable snap ring pliers.

Figure 7B2-78

3. Install the two halves of gear and bearing

separator plates, Tool No. J 36513 under 3rd

speed constant mesh gear and secure with

the two clamp bolts.

4. Support the separator plates, then press the

mainshaft assembly from the 3rd speed

constant mesh gear, 3rd speed synchromesh

ring and the 3rd/4th synchromesh assembly.

Figure 7B2-79

5. Remove the selective snap ring (1) and spacer

washer (2) from the rear of the mainshaft.

Figure 7B2-80

6. After fitting suitable press plates such as J-

22912-01 and supporting adequately, press

the mainshaft from the rear bearing.

NOTE:

As the removal of this bearing from the rear

transmission housing and this pressing operation

will brinell this ball race, it must be replaced with a

new component on reassembly.

Figure 7B2-81

7. Remove 5th speed constant mesh gear (1),

synchromesh ring (2) and caged needle roller

(3) from the mainshaft.

NOTE:

The needle roller cage is split to enable removal

over the step in the mainshaft.

Figure 7B2-82

8. Remove the selective snap ring (1) securing

the 5th/Reverse synchromesh assembly (3),

from the mainshaft, using suitable snap ring

pliers (2).

Figure 7B2-83

9. Using two large, f lat bladed srewdrivers , gently

lever the Reverse speed, constant mesh gear

and 5th/Reverse synchromesh assembly from

the mainshaft.

NOTE 1:

The synchromesh assembly is not a tight

interference fit on the mainshaft and is easily

removed.

Figure 7B2-84

NOTE 2:

When separating the 5th/Reverse synchro-mesh

assembly from Reverse gear (1), take care not to

lose any of the twelve (12), 4 mm balls (2) located

in three groups of four around the Reverse

synchromesh ring (3).

Figure 7B2-85

11. Remove the selective snap ring from the

mainshaft, securing the 2nd speed constant

mesh gear, roller bearing sleeve and thrust

washer.

Figure 7B2-86

12. Install the two halves of gear and bearing

separator plates, Tool No. J 36513 under the

1st speed, constant mesh gear, with the flat

side (stam ped ‘B’) facing the gear. Secure the

plate halves with the two clamp bolts.

13. Support the separator plates and press the

mainshaft from the following components:

•2nd speed constant mesh gear, roller

bearing sleeve and thrust washer.

•2nd speed constant mesh gear.

•2nd speed constant mesh gear, caged

needle roller bearing.

•2nd speed constant mesh gear,

synchromesh ring.

•1st/2nd speed synchromesh assembly.

•1st speed constant mesh gear,

synchromesh ring.

•1st speed constant mesh gear.

14. Remove the caged needle roller bearing from

the mainshaft.

Figure 7B2-87

MAINDRIVE GEAR

1. Remove the caged needle roller bearing from

the maindrive gear.

Figure 7B2-88

CLUSTER GEA R

While the cluster gear is made up from two

separate components, it is only serviced as a

complete assembly. It should therefore, not be

dismantled. The assembly of the components is

precise and cannot be duplicated.

REVERSE IDLER GEAR SHAFT

1. Remove the snap ring from the cut-away end

of the reverse idler gear shaft, then remove

the two caged needle roller bearings from the

shaft.

Figure 7B2-89

2. Slide the thrust washer from the reverse idler

gear shaft, taking care not to lose the locating

ball (arrow) from the shaft.

3. Remove the remaining snap ring from the

reverse idler gear shaft.

Figure 7B2-90

SYNCHROMESH ASSEMBLIES

First, mark the relationship of the outer sleeve (2)

to the synchromesh hub (1), using felt tipped pen or

similar. Not only will this ‘index’ the sleeve to the

hub but it will also ensure that any offsets in the

sleeve and/or hub, will be maintained on

reassembly.

Then, wrap the assembly loosely in a clean cloth,

support the outer sleeve with the left hand and

push the hub assem bly down, using the right hand.

Be careful not to lose any of the springs (5), balls

(4) or sliding keys (3).

NOTE:

While the synchromesh assembly shown is for the

1st/2nd speed ranges, the disassembly process is

the same for each of the remaining two

assemblies.

Figure 7B2-91

INSPECT COMPONENTS

1. Check synchromesh rings for cracks and for

deformation. Inspect rings for excessive wear

in the areas shown.

2. Check synchromesh hubs, outer sleeves,

sliding blocks and synchromesh springs for

damage.

Figure 7B2-92

3. Check each synchromesh ring for wear by

mounting the ring to the respective gear and

measure the gap as shown.

NOTE:

To obtain an accurate measurement, the

synchromesh ring must be held squarely and fully

installed to its gear, as illustrated. Then, using

feeler gauges, measure the gap in at least three

places around the circumference. Average the

readings and use this figure to assess the

synchromesh ring wear.

Specifications for each synchromesh ring are as

follows and correspond to the synchromesh

assemblies indicated next. Figure 7B2-93

POSITION GEAR SERVICEABLE WEAR

LIMIT

(A) 4th 1.35 - 1.95 mm

(B) 3rd 1.35 - 1.95 mm

(D) 1st 1.35 - 1.95 mm

(E) Reverse 1.00 - 1.40 mm

(F) 5th 1.35 - 1.95 mm

Figure 7B2-94

NOTE:

With the exception of the Reverse synchromesh

ring, all others are the same part. Even so, unless

they are to be replaced, it is s ound practic e to k eep

each ring with its respective gear , to preserve wear

patterns.

4. Inspect all gears, sleeves, hubs, rings and

shafts for wear, scoring, pitting, c hips, nick s or

burrs. Slight s cores or bur rs m ay be honed off

with a fine stone, however if a gear is chipped

or unduly worn it must be replaced.

5. Inspect all needle roller bearings for wear or

damage.

NOTE:

As needle roller wear can be difficult to see, it is

good practice to r eplace all roller bear ings where a

substantial distance has been covered by the

transmission.

6. Inspect the mainshaft surfaces, roller bearing

inner sleeves and internal surfaces of the

gears where the needle bearings come into

contact.

REASSEMBLE

A. SYNCHROMESH ASSEMBLIES

The respective synchromesh assemblies are to be

assembled before pressing onto the mainshaft.

Only one synchromesh assembly is described in

the following operations, since reassembly is

similar for all units.

1. Support the synchromesh hub over a suitable

disc to raise it from the bench surface and

install the outer sleeve over the synchromesh

hub.

2. Insert sliding keys (2) and the pressure

springs (3), into each of the locations in the

synchromesh hub. Use petroleum jelly to hold

parts in place.

3. Using a small screwdriver, prise each key (2)

upwards, just sufficient to enable a ball (1) to

be inserted. While holding the ball inwards,

push the k ey down to captur e the ball. Repeat

for the remaining two key/spring combinations.

Assembly Notes:

NOTE 1:

The single groove on the outer sleeve of the

3rd/4th synchromesh outer sleeve, faces 4th gear.

The hub is symm etric al and has the s m allest inside

diameter.

NOTE 2:

The 1st/2nd gear synchromesh outer sleeve and

hub are both symm etrical. The outer sleeve has an

inscription “FIRST GEAR SIDE” for assembly.

NOTE 3:

The single groove on the outer sleeve of the

5th/Reverse synchromesh outer sleeve, faces

Reverse gear. The side of the hub facing the

Reverse gear synchromesh ring, containing the

twelve balls, has a recess machined into the inner

side of the outer section.

Figure 7B2-95

B. MAINSHAFT

1. Coat mainshaft, all gear bores and needle

bearings with transmission lubricant.

2. With the mainshaft supported in a vertical

position, install 1st speed gear caged needle

roller bearing, 1st speed gear (1) and

synchromesh ring onto mainshaft.

3. Install the 1st/2nd synchromesh assembly (2)

onto the mainshaft, engaging the splined

teeth, with the outer sleeve inscription “FIRST

GEAR SIDE”, facing first gear.

4. Using a suitable sleeve (3), press

synchromesh hub onto mainshaft, ensuring

that synchromesh ring slots align with sliding

keys.

5. Remove m ainshaf t from press , and check that

the 1st speed synchromesh ring is not jammed

on the gear cone.

Figure 7B2-96

6. Install 2nd speed synchromesh ring, ensuring

that the ring is indexed correctly with the

synchromesh hub assembly.

7. Install the 2nd speed gear (2) and caged

needle roller bearing, onto the flanged bearing

sleeve.

8. While supporting the 2nd speed gear

assembly, press the flanged sleeve onto the

mainshaft, using a suitable length of pipe (1),

as shown.

9. Remove m ainshaf t from press , and check that

the 2nd speed synchromesh ring is not

jammed on the gear cone.

Figure 7B2-97

10. Install selective snap ring to the mainshaft,

securing the 2nd speed gear, flanged bearing

sleeve. Make sure the snap ring is seated

correctly in groove.

Snap rings are available in thicknesses of 2.0,

2.05, 2.1, 2.15, 2.2, 2.25 and 2.3 mm.

Figure 7B2-98

11. Install caged needle roller bearing, 3rd speed

constant mesh gear (3) and synchromesh ring,

onto mainshaft.

12. Preheat assembled 3rd/4th speed

synchromesh assembly on a hot plate to

approximately 100 °C.

NOTE:

Use Faber Castell Thermochrom 2815/100 °C

around synchromesh hub, to indicate temperature.

13. Using a heat proof glove, position

synchromesh assembly (2) onto mainshaft,

aligning mainshaft and hub splines.

14. Using suitable sleeve (1), press synchromesh

hub assembly onto mainshaft, while holding

3rd speed gear and synchromesh ring into

place against the synchromes h hub, to ensure

that synchromesh ring aligns with sliding keys.

15. Remove m ainshaf t from press , and check that

the 3rd speed synchromesh ring is not

jammed on the gear cone.

Figure 7B2-99

16. Using suitable snap ring pliers (1), install new

selective snap ring (2) to mainshaft, ensuring

that snap ring is correctly seated in groove

with no clearance between the snap ring and

the synchromesh hub (3).

Snap rings are available in thicknesses of 1.8,

1.85, 1.9, 1.95 and 2.0 mm.

Figure 7B2-100

17. Install the 5th/Reverse synchromesh

assembly, over the Reverse, constant mesh

gear and synchromesh ring, as shown. Note

that the twelve balls have previously been

installed.

NOTE:

To retain the twelve ball bearings around the

Reverse synchromesh ring, lightly coat each one

with petroleum jelly (such as Vaselineä or

equivalent).

Figure 7B2-101

18. Install the Reverse gear needle bearing (2)

and pre-assembled gear and synchromesh

assembly (1) to the mainshaft.

Figure 7B2-102

19. Using suitable sized tube (4) and press plates,

press mainshaft into synchromesh hub (3). In

the attitude shown, the position of the Rever se

gear (2) will ensure that synchromesh ring

slots align with the sliding keys in the

synchromesh assembly.

20. Remove m ainshaf t from press , and check that

the Reverse synchromesh ring is not jammed

on the gear cone.

Figure 7B2-103

21. Install a new, 5th/Reverse synchromesh

assembly selective snap ring (1) onto

mainshaft, using suitable snap ring pliers (2).

Ensure that no gap exists between the

synchromesh hub and the installed snap ring.

Make sure the snap ring is seated correctly in

groove.

Snap rings are available in thicknesses of 2.0,

2.05, 2.1, 2.15 and 2.2 mm.

Figure 7B2-104

23. Install the 5th speed gear (1), caged needle

roller race, 5th speed synchromesh ring and

5th speed gear onto the mainshaft.

24. Install the rear bearing retaining plate (2) and

a new, rear mainshaft bearing (3) over the

mainshaft. Then, using a suitable diameter

pipe (36 mm I.D.), supported over press

plates, press the mainshaft into the bearing.

NOTE:

As it cannot be installed afterwards, the bearing

retainer plate (2) must be installed before pressing

the bearing fully onto the mainshaft .

25. Install the spacer washer over the mainshaft,

then install a new, selective snap ring to the

mainshaft ensuring that snap ring is correctly

seated in groove with no clearance between

the snap ring and the synchromesh hub.

Snap rings are available in thicknesses of 2.0,

2.1, 2.2 and 2.3 mm. Figure 7B2-105

MAINDRIVE GEAR

1. Coat maindrive gear needle bearing with

petroleum jelly.

2. Insert bearing assembly into the maindrive

gear.

Figure 7B2-106

REVERSE IDLER GEAR SHAFT

1. Install a new snap ring into the shaft groove

closest to the locating ball end (Not shown).

2. Install locating ball (arrow) into the shaft,

securing with petroleum jelly (such as

Vaselineä or equivalent).

3. Install thrust washer over the locating ball.

Figure 7B2-107

4. Lubricate the reverse idler gear shaft with

clean transmission fluid, then install the two

caged needle roller bearings.

5. Locate the roller bearings by installing new

snap rings to eac h groove on the reverse idler

gear shaft.

Figure 7B2-108

TRANSMISSION CASE REAR SECTION

DISASSEMBLE

1. To remove the rear oil seal (1), use Tool No.

E308 or similar.

NOTE:

An alternative method is to use a small, sharp cold

chisel and hammer to pierce the seal. Then, use

the chisel as a lever to remove the seal from the

transmission case .

Figure 7B2-109

NOTE:

Unless the rear transmission case bush is to be

replaced, there is no need for this next operation.

2. Preheat the transmission housing in the rear

bush area, to approximately 80 °C using a

commercially available hot air blower.

NOTE:

Use Faber Castell Thermocrom 2815/80 °C, to

ensure that an excessive temperature is not

reached.

3. Using Tool 7AT5 with driver handle, Tool

7AT2, press the bush from the transmission

case.

Figure 7B2-110

4. To remove the rear cluster gear bearing cup,

use the following method;

a. Grind the legs of Tool KM-328-7-A down

to approximately 3 mm , s uf ficient to inser t

under the bearing cup.

b. Install each of the modified legs of Tool

KM-328-7-A under the bearing cup, then

insert spacer Tool KM-328-9 in between

them.

c. Use the cup, Tool KM-328-5-1A and pin

from slide hammer Tool KM-328-B, to

secure the legs and spacer assembly.

d. Screw threaded adaptor into cup and

install puller KM-556-1A.

e. Use the puller to extract the bearing cup

from the rear transmission case.

NOTE:

To aid in removal of bearing, it is recommended

that the case area around the bearing be pre-

heated to 80 °C, using a commercially available,

hot air blower.

Use Faber Castell Thermocrom 2815/80 °C, to

ensure that an excessive temperature is not

reached.

Figure 7B2-111

INSPECT

1. Inspect rear transm ission cas e for any defects

or cracks that may cause oil leaks.

2. Check all machined surfaces for burrs, and if

present, dress them off with a fine cut file.

3. Check bearing bores for damage or scoring.

4. Inspect all shift control component contact

surfaces and sliding surfaces for wear,

scratches, projections or other damage.

5. Check all springs for damage or distortion.

6. Check the selector inter-lock pin and balls for

damage.

REASSEMBLE

1. Using adaptor Tool KM454-1, installed onto

driver handle T ool KM- 454-4 with a flat washer

(1) in between, press the rear cluster bearing

cup into the rear transmission case.

NOTE 1:

To assist in the installation of the bearing, heat the

rear transmission housing with a commercially

available hot air gun to approximately 80 °C.

Use Faber Castell Thermocrom 2815/80 °C, to

ensure that an excessive temperature is not

reached.

Figure 7B2-112

2. Preheat the transmission housing in the rear

bush area, to approximately 80 °C using a

commercially available hot air blower.

NOTE:

Use Faber Castell Thermocrom 2815/80 °C, to

ensure that an excessive temperature is not

reached.

3. Using Tool 7AT5 with driver handle, Tool

7AT2, press a new bush into the transmission

case, aligning the oil grooves as shown.

Figure 7B2-113

4. After lubricating the seal lip with transmission

lubricant, lightly smear Loctite 574 sealant (or

equivalent, to Holden’s Specification HN2216)

around the outer seal surface.

5. Use previously released Tool No. J-21426 (or

similar) and install the new seal into the rear

transmission case .

Figure 7B2-114

TRANSMISSION CASE FRONT SECTION

DISASSEMBLE

1. Insert the legs of Tool KM328-7 into the

bearing and hold in position with spacer, Tool

KM-328-9. Slip the cup, Tool KM-328-5-1A

over the legs and secure with the pin.

2. Screw the thread of slide hammer, Tool No.

KM-328-B into the cup and remove the

gearshift selector rod front bearing from case.

NOTE:

When carrying out this operation, the bearing will

be damaged and must be replaced.

Figure 7B2-115

3. From inside the transmission bell housing,

remove the bolt securing the reverse block

assembly (‘2’ in the previous illustration).

To remove the reverse block shaft, use a pin

punch to gently tap the shaft free from the

transmission front case.

NOTE:

Use a thin (3 m m) pin punch that will bottom in the

thread hole and not damage the screw thread.

Figure 7B2-116

NOTE:

This next operation is only be considered

necessary if replacement of the front cluster gear,

bearing and/or transmission front case was

required.

4. From inside the transmission case, insert a

large pin punch through the hexagonal hole in

the front cluster gear bearing cup and drive the

sealing cap from the case,

5. Remove cluster gear front bearing circlip (2)

from front transmission case, using suitable

circlip pliers (1) and remove any end float

adjusting shim/s.

NOTE:

If necessary, press bearing inward slightly so that

snap ring can be removed. Use adaptor, Tool KM-

454-1 and mandrel Tool KM-454-4, with a flat

washer (See next illustration). Figure 7B2-117

6. Use the adaptor, Tool KM 454-1 and driver

handle Tool KM-454-4, with a flat washer (1)

press the bearing cup into the transmission

case.

NOTE:

If these tools are not available, a suitable sleeve of

43 mm outside diameter, could be used.

Figure 7B2-118

7. Using a suitable adaptor or sleeve (2) and

driver handle (1), press the maindrive gear

bearing from inside the transmission case, to

remove it.

NOTE:

As insufficient space is available to allow removal

by pressing on the outer bearing ring, the balls will

be brinelled in the removal process. Therefore, the

bearing MUST be replaced.

Figure 7B2-119

INSPECT

1. Inspect transmission case for any defects or

cracks that may cause oil leaks.

2. Check all machined surfaces for burrs, and if

present, dress them off with a fine cut file.

3. Check bearing bores for damage or scoring.

REASSEMBLE

1. Lubricate a new gearshift lever shaft guide

bearing (1) with transmission fluid. Install,

using Tool KM-409-A or equivalent.

Figure 7B2-120

2. Install a new circlip to the bore of the front

cluster gear bearing, then install the

compensating shim/s, previously removed.

3. Install cluster gear front bearing, using

adaptor, Tool KM-454-1, flat washer (1) and

driver handle KM-454-4 (or a suitable sized

tube), pressing from the inside of the front

transmission housing, outward.

NOTE 1:

If a new transmiss ion cas e f ront s ec tion and/or new

cluster gear is to be installed, the end play m ust be

measured.

Refer to the Sub-Asse m bly heading ‘Cluster Gear

End Play Adjustment', next in this Section.

NOTE 2:

If the maindrive bearing was removed and a

replacement is to be installed, then compensating

shim thickness will need to be calculated, after

installation. As bear ing replacem ent would nor m ally

be carried out during tr ansmiss ion reassembly, this

operation will be detailed during this procedure.

Figure 7B2-121

CLUSTER GEAR END PLAY ADJUSTMENT

This operation is only necessary when replacing

the front transmission case and/or the cluster gear.

1. Install cluster gear into transmission case rear

section.

Figure 7B2-122

2. Remove cluster gear front bearing circlip (2)

from front transmission case, using suitable

circlip pliers (1) and remove any end float

adjusting shim/s.

NOTE:

If necessary, press bearing cup inward slightly to

enable removal of snap ring.

Figure 7B2-123

3. Install cluster gear f ront bear ing c irclip, without

shim/s.

4. Using adaptor, Tool KM-454-1 and mandrel

KM-454-4, together with a flat washer (1) (or a

suitable tube), press bearing into case bore

until it contacts snap ring.

Figure 7B2-124

5. Place transmission case front section onto

rear section and install four case attaching

bolts (arrows). Tighten bolts to the correct

torque specification.

TRANSMISSION REAR CASE

ATTACHING BOLT 25 Nm

TORQUE SPECIFICATION

Figure 7B2-125

6. Secure a piece of flat steel (3) (approximately

20 x 5 mm) with two bolts, to the front

machined surface of the clutch throwout

bearing guide flange.

7. Mount a dial indicator (1) and stand (2) to the

flat steel (3), ensuring that the stylus of dial

indicator res ts on the nose of the cluster gear .

Access is through the hexagonal hole in the

front bearing cup, as shown. Zero the dial

indicator.

Figure 7B2-126

8. Insert a screwdriver through filler plug

opening, then raise and lower cluster gear to

obtain the total end float dimension. Record

this reading.

Axial play should be to the following specification:

CLUSTER GEAR AXIAL PLAY 0.12 - 0.22 mm

9. Subtract this axial play figure from the

measurement taken to determ ine the required

shim stack.

e.g. Total Axial Play Recorded = 3.96 mm

Subtract Axial Play

Specification = 0.18 mm

Required Shim Thickness = 3.78 mm

Shims are available in 1.7 mm, 1.8 mm, 2.0

mm, 2.1 mm and 2.2 mm thicknesses. In the

above example, a shim combination of 1.8 and

2.0 mm would be required.

10. Install selected shim/s, refer Transmission

Case Front Section-Disassemble and

Reassemble in this Section.

11. Recheck axial play as described previously.

12. Once axial play has been adjusted, separate

the two transmission cases and remove the

cluster gear.

Figure 7B2-127

CLUTCH THROWOUT BEARING GUIDE

INPUT SHAFT SEAL, REPLACE

1. Remove the maindrive bearing compensation

shim/s (2) if fitted, from the throwout bearing

guide and set to one side. If the maindrive

bearing is not replaced, then this same shim

stack will need to be reinstalled, on

reassembly.

2. Wrap some adhesive tape around a

screwdriver shaft (1), then use it to lever seal

(3) from thrust bearing guide sleeve, as

shown. Take care not to scratch the seal

surf ace nor damage the m achined flat s urface

of the throwout bearing guide during this

process.

Figure 7B2-128

3. Using a suitable size sleeve (2, install new

seal into guide sleeve (3).

Figure 7B2-129

‘O’ RING, REPLACE‘

1. While holding the flange (3) against a flat

surface, use a plastic faced hammer (1) and

tap the throwout bearing guide (2) from the

mounting flange.

NOTE 1:

As the throwout bearing guide may be a very tight

fit, this operation may have to be achieved by

pressing the guide from the mounting flange.

NOTE 2:

Do not lose the small indexing disc.

Figure 7B2-130

2. Remove the O -ring seal (1) f rom the m ounting

flange (2), using a small screwdriver.

3. Clean all components and inspect for wear

and damage. Replace as required.

4. Install new O-ring (1) into the flange,

lubricating with petroleum jelly.

Figure 7B2-131

5. Align the locating disc semi-c ircular c ut-outs of

the flange and guide and press the throwout

bearing guide (3), into the cover, using a

suitable sleeve (2). Take care to keep both

parts square to each other.

6. Install the locating disc (1), securing with a

small amount of petroleum jelly.

Figure 7B2-132

4.5 TRANSMISSION REASSEMBLE

1. Assemble the two adaptors Tool J 36515-15

(mainshaft adaptor) and Tool J 36515-16

(cluster gear adaptor), to the Assembly Pallet,

Tool J 36515.

2. With all synchromesh assemblies in the

neutral position, install all assembled shift

forks and r ails to their r es pec tive synchrom es h

rings.

3. Check that the interlock pin is installed in the

hole through the 3rd/4th shift rail and secure

with petroleum jelly.

4. After assembling the maindrive gear, cluster

gear and reverse idler assembly to the

mainshaft assembly, hold everything together

as a single assembly and mount on the

Assembly Pallet, Tool J 36515, as shown.

Install a heavy elastic band (1) around the

geartrain and Reverse idler gear assembly to

hold everything in place.

5. Install two fabricated guide studs (2) into the

rear mainshaft bearing retainer plate, in the

positions shown.

NOTE:

While 75 mm length studs are adequate, 100 mm

lengths are easier to guide into the rear case. In the

positions shown, either length is suitable but the

longer studs will not be removable from the third

hole, shown here, as vacant, after assembly to the

rear case.

Figure 7B2-133

6. Pre-heat the rear bearing counterbore in the

rear housing to 80 °C, using a commercially

available hot air blower.

NOTE:

Use Faber Castell Thermocrom 2815/80 °C to

indicate the temperature of the bearing surface.

Figure 7B2-134

5. Carefully lower the rear transmission case

over the geartrains and rails, aligning the shift

rails with their respective bores and the guide

studs into the rear case holes.

NOTE:

Provided the transmission case was pre-heated,

installation eff ort should be m inimal but tapping the

case with a soft faced hammer might prove useful

to fully seat the rear bearing.

Once the rear transmission case is fully

installed, cut the elastic band and remove.

Figure 7B2-135

6. Hold the rear bearing plate into position by

grasping one of the guide studs (2) with a pair

of combination pliers and apply a rearward

force.

7. Apply thread sealant such as Loctite 242 or

243 (or equivalent to Holden’s Specification

HN 1256) to the threads of one of the three,

60 x M8, Allen key headed bolts (1), then

apply sealant such as Loctite 574 (or

equivalent to Holden’s Specification HN 2216)

under the head of the bolt.

8. Carefully install the bolt into the remaining

location, as shown but do not tighten at this

stage.

9. With a suitable scr ewdriver, r emove one of the

guide studs (2) and replac e with another of the

Allen key headed bolts, with sealant applied as

for the first bolt.

10. Repeat steps 7 and 8 for the remaining bolt.

11. When all three bolts are installed, tighten to

the correct torque specification.

REAR MAINSHAFT BEARING

RETAINING PLATE BOLT 20 Nm

TORQUE SPECIFICATION

Figure 7B2-136

12. After checking that the detent pin through the

3rd/4th shift rail has not become dislodged,

install the two interlock balls (3) into their

respective holes, followed by the two plugs (2).

NOTE:

Provided the plugs are almost flush with the

machined case surface, then the detent balls will

be fully home in their bores. If not, then remove

them and determine the reason why. Invariably the

detent pin will have been dislodged from the c entral

position in the shift rail.

13. Install the three detent balls (1) into their

respective holes, as shown.

Figure 7B2-137

14. Insert the three detent ball, pressure springs

(2) into the transmission case.

15. Apply thread sealant such as Loctite 242 or

243 (or equivalent, to Holden’s Specification

HN 1256) to the cleaned threads of the

attaching bolts, then install pressure spring

cover (1) and tighten bolts to the correct

torque specification.

SHIFT DETENT SPRING COVER 10

BOLT TORQUE SPECIFICATION Nm

Figure 7B2-138

16. Apply thread sealant such as Loctite 242 or

243 (or equivalent, to Holden’s Specification

HN 1256) to the cleaned threads of the

Reverse idler gear shaft attaching bolts.

17. Apply sealant such as Loctite 574 (or

equivalent to Holden’s Specification HN 2216)

under the head of the front bolt (3), then

loosely install both bolts, while supporting the

shaft and the front support.

18. While inserting a 0.XX mm feeler gauge strip

between the reverse idler gear and the thrust

washer, push the reverse idler gear shaft

rearward and tighten both retaining bolts to the

correct torque specification.

REVERSE IDLER GEAR SHAFT

RETAINING BOLT 25 Nm

TORQUE SPECIFICATION Figure 7B2-139

19. Install loading Tool AU462 to pre-assemble

the selector arm, spring, bush and sleeve, as

follows;

a. Insert the shaft (1) into the rear of the

selector arm (2), engaging the lugs with

those on the arm.

b. Install the spring (5), inser ting the straight

end through the hole in the selector arm

pin, then the sleeve and selector rod bus h

(4).

c. Insert the sleeve of Tool AU462 over the

protruding shaft, engaging the leg with the

free end of the spring (5

d. While holding the selector lever (2 one

hand rotate the sleeve of Tool AU462,

counter-clockwise, loading the spring (5).

Tighten the locking screw (3), retaining

the spring in a tensioned state. Figure 7B2-140

20. Install the selector arm roller to the pin,

securing with petroleum jelly.

21. Apply transmission lubricant to the bearing

surface of the selector arm, then carefully

insert the loaded shift mechanism and Tool

AU462 into the rear transmission case. Take

care not to lose the roller nor c ock the selec tor

arm in the case bore during the installation

process.

Figure 7B2-141

22. Apply thread sealant such as Loctite 242 or

243 (or equivalent, to Holden’s Specification

HN 1256) to the cleaned threads of the

gearshift selector rod bush lock bolt, before

installing it and tightening to the correct torque

specification.

GEARSHIFT SELECTOR ROD

BUSH LOCK BOLT 25 Nm

TORQUE SPECIFICATION

Figure 7B2-142

23. Install the lock ing lever spring, sc rew plug and

spring guide into the transmission case after

applying thread sealant s uch as Loctite 242 or

243 (or equivalent, to Holden’s Specification

HN 1256) to the cleaned threads of the screw

plug. Tighten the screw plug to the correct

torque specification.

LOCKING LEVER SCREW PLUG 60

TORQUE SPECIFICATION Nm

Figure 7B2-143

24. Apply a thin coating of petroleum jelly to

gearshift operating shaft rollers, then install

shaft into the r ear of the tr ansm iss ion housing,

aligning the rollers with the internal selector

arm and the shaft with the selector arm bush.

25. Align the selector arm (1) roll pin hole with the

selector shaft (3) hole, support the shaft (3)

with a suitable size wooden wedge (2), then

install a new roll pin to the arm (2) and shaft

(3).

Figure 7B2-144

26. Lubricate gearshift shaft seal lips with

transm ission fluid. Install the seal into the rear

transm ission case, using a suitable length and

size of tubing, until the seal is f lus h agains t the

rear transmission housing.

27. Install gearshift trunnion to the gearshift

selector rod shaft and secure with the retaining

pin.

28. Lever the spring steel retaining ring over the

pin, then rotate to completely cover the pin.

29. Select 4th gear and check that all remaining

synchronisers are loosely seated against their

respective gear cones. If necessary, loosen

firmly seated ring/s from gear cone/s.

Figure 7B2-145

30. Preheat transmission case front section in

area of m aindrive bearing to approxim ately 80

°C using a commercially available hot air

blower.

NOTE:

Use Faber Castell Thermochrom 2815/80 °C to

indicate temperature. Apply Thermochrom around

bearing area of transmission case.

31. Using a suitable disc and driver handle (or a

suitable diameter piece of pipe), acting on the

outer bearing ring, press bearing fully home

into the bearing bore in the transm ission case

front section.

32. Install reverse block assembly to the

transmission case, by using a plastic faced

hammer. Apply Loctite 574 (or equivalent to

Holden’s Specification HN2216) to the sealing

surface of the retaining bolt. Tighten to the

correct torque specification.

REVERSE BLOCK BOLT TO

TRANSMISSION FRONT CASE 10 Nm

TORQUE SPECIFICATION

Figure 7B2-146

33. Apply petroleum jelly to the rollers of the front

cluster shaft bearing and install into the front

bearing cup.

NOTE:

The needle roller cage with the heavier side, faces

out of the bearing cup.

34. Apply a bead of Loctite 574 sealant or

equivalent (to Holden's Spec ification HN2216),

to sealing surface of one transmission case.

35. Preheat the centre of the maindrive bearing in

the transmission case front section to

approximately 80 °C using a commercially

available hot air gun.

NOTE:

Use Faber Castell Thermochrom 2815/80 °C to

indicate temperature. Apply thermochrom around

the bearing centre.

36. Install the round magnet into position in the

front transmission case, then immediately

position rear transmission assembly onto the

front c ase, aligning shif t rods with f ront section

bore holes.

Figure 7B2-147

37. Install a sleeve (2) such as AKM-500-3 over

the input shaft, then Tool KM-461 as shown.

Draw the input shaft into the front bearing,

using a socket bar.

NOTE:

The arm on Tool KM-461 may need to adjusted to

stop the lower half of the tool from rotating.

38. Rem ove Tool No. KM-461 and inst all selective

spacer washer and retaining ring to maindrive

gear.

Selective spacer washers are available in

thicknesses of 2.10, 2.20, 2.30, 2.40 and 2.50

mm.

39. Install a new plug to the front cluster gear

bearing opening, ensuring that it is s quare and

installed to the circlip.

40. With the transmission in neutral, rotate

maindrive gear to check that no synchroniser

rings have become jammed on gear cones. Figure 7B2-148

41. Install new dowel pins (2) to align the f r ont and

rear transmission cases, prior to installing and

tightening the attaching bolts to the correct

torque specification.

TRANSMISSION REAR CASE

TO FRONT CASE BOLT 25 Nm

TORQUE SPECIFICATION

Note the location of the five longer (45 mm)

bolts (3).

Figure 7B2-149

42. Prior to installing the clutch throwout bearing

guide, the compensating shim thickness must

be determined, as follows:

a. With the front bearing distance ring

installed, use a vernier depth gauge and

measure the distance between the front

edge of the bearing distance ring and the

transmission case, noting the

measurement.

Figure 7B2-150

b. After removing any shims, measure the

depth of the counterbore in the clutch

throwout bearing guide, noting the

measurement.

c. Subtract measurement ‘a’ from ‘b’ to

determine the compensating shim stack

required.

e.g. Front Bearing Ring Protrusion = 5.5 mm

Throwout Counterbore Depth = 6.0 mm

Shim thickness = 0.5 mm

Selective shim s are available in thic knes ses of

0.30, 0.40 and 0.50 mm.

Figure 7B2-151

43. Apply a thin coating of Loctite 574 (or

equivalent to Holden’s Specification HN2216),

to the mounting face of the clutch throwout

bearing retaining plate.

44. Lubricate seal with transmission fluid, then

install throwout bearing guide assembly.

45. Apply sealant such as Loctite 574 (or

equivalent to Holden’s Specification HN2216),

to the cleaned threads of the fas tening bolts to

the correct torque specification.

THROWOUT BEARING GUIDE

ASSEMBLY BOLT 10 Nm

TORQUE SPECIFICATION

NOTE:

The bearing guide assembly is installed in the

correct position when the arrow on the cover, points

directly to the cluster gear bearing plug.

Figure 7B2-152

46. Lubricate thrust bearing guide sleeve,

maindrive gear teeth, release fork, thrust

bearing and ball headed pin with high

temperature grease. Refer

Section 7A, CLUTCH.

47. Install clutch thrust bearing to the clutch

release fork, then install the bearing/fork

assembly, securing to the pivot ball with the

spring clip.

48. Push the bearing fully in, to maintain position

on the fork, until the transmission is installed

and the slave cylinder is reinstalled.

Figure 7B2-153

49. Insert detent pin and pressure spring into

transmission case .

NOTE:

Ensure that detent pin is installed with roller in a

horizontal position, as shown.

50. Install detent spring closure plug, after coating

with sealant such as Loctite 574 (or

equivalent, to Holden’s Specification HN2216).

Figure 7B2-154

51. Install back-up lamp switch to transmission

case and tighten to the correct torque

specification.

BACK-UP LAMP SWITCH 20

TORQUE SPECIFICATION Nm

Figure 7B2-155

52. Install drain plug (2) and tighten to the correct

torque specification.

TRANSMISSION DRAIN PLUG 40 - 60

TORQUE SPECIFICATION Nm

53. Fill transmission with approximately 1.8 litres

of an 80W gear oil to Holden's Specification

HN 1855, such as Castrol VMX80W or

equivalent.

54. Install filler plug (1) and tighten to the correct

torque specification.

TRANSMISSION FILLER PLUG 25

TORQUE SPECIFICATION Nm

Figure 7B2-156

55. Reinstall the gearshift brace bracket (1) to the

rear transmission case and tighten the

attaching bolts (2) to the correct torque

specification.

GEARSHIFT BRACE BRACKET TO

TRANSMISSION BOLT 15 - 35 Nm

TORQUE SPECIFICATION

Figure 7B2-157

56. Install rear mount adaptor plate to

transmission case rear section . Tighten

attaching bolt (2) to the correct torque

specification.

REAR TRANSMISSION CASE

ADAPTOR PLATE BOLT 95 - 115 Nm

TORQUE SPECIFICATION

NOTE:

If the rear engine mounting (1) was removed from

the mounting bracket, reinstall the attaching nuts

and tighten to the correct torque specification.

REAR ENGINE MOUNT TO

TRANSMISSION MOUNTING PLATE 50 - 65 Nm

NUT TORQUE SPECIFICATION

57. Reinstall transmission into vehicle. Refer to

4.2 TRANSMISSION ASSEMBLY, Reinstall,

in this Section.

Figure 7B2-158

5. DIAGNOSIS

CONDITION PROBABLE CAUSE CORRECTION

TRANSMISSION

SHIFT

HARD/HEAVY

Clutch pedal high effort.

Shifter shaft binding.

Internal bind in transmission

caused by shift forks, selector

shafts or synchromesh

assemblies.

Incorrect lubricant.

Lubricate or replace as required.

Check for mispositioned shift

fork roll pin/s, loose bolts, worn

shifter shaft or shaft bores or

distorted oil seal.

Repair as necessary.

Remove, disassemble and

inspect transmission. Replace

worn or damaged components

as necessary.

Drain and refill transmission.

GEAR CLASH

WHEN SHIFTING

FROM ONE GEAR

TO ANOTHER

Lubricant level low or

incorrect lubricant.

Gearshift components or

synchromesh assemblies

worn or damaged.

Drain and refill transmission and

check for lubricant leaks if level

was low. Repair as necessary.

Remove, disassemble and

inspect transmission. Replace

worn or damaged components

as necessary.

TRANSMISSION

NOISY Lubricant level low or

incorrect lubricant has been

used.

Transmission housing to

engine attaching bolts loose.

Gearshift mechanism,

transmission gears or bearing

components worn or

damaged.

Drain and refill transmission. If

lubricant was low, check for

leaks and repair as necessary.

Check and correct bolt torque

settings as necessary.

Remove, disassemble and

inspect transmission. Replace

worn or damaged components

as necessary.

JUMPS OUT OF

GEAR Gearshift mechanism, shift

forks, selector shafts,

interlock pin, detent

balls/springs, worn or

damaged.

Gear teeth worn or tapered,

synchromesh assemblies

worn or damaged. Excessive

end play in components.

Remove, disassemble and

inspect transmission assembly.

Replace worn or damaged

components as necessary.

Remove, disassemble and

inspect transmission. Replace all

worn or damaged components

as necessary.

WILL NOT SHIFT

INTO ONE GEAR Gearshift selector shaft/s,

interlock pin, balls or selector

arm, worn, damaged or

inco rrectly assembled.

Synchromesh sleeves or

hubs, worn or damaged.

Remove, disassemble and

inspect transmission selector

assemblies. Repair or replace

components as necessary.

Remove, disassemble and

inspect transmission. Replace

worn or damaged components.

Techline

CONDITION PROBABLE CAUSE CORRECTION

LOCKED IN ONE

GEAR -

CANNOT BE

SHIFTED OUT

Shift shaft/s worn or

damaged, selector fork bent

or broken.

Gearshift mechanism worn,

damaged or broken. Worn or

damaged gear train

components.

Inspect and replace worn or

damaged components.

Disassemble transmission.

Replace damaged parts or

assemble correctly.

TRANSMISSION

WILL NOT SHIFT

INTO REVERSE

(ALL OTHERS OK)

Worn or damaged internal

components.

Reverse block mechanism

jammed

Remove transmission. Check for

damaged reverse gear train

components.

Dismantle transmission, inspect

and replace components as

necessary.

6. SPECIFICATIONS

TRANSMISSION:

V8 Powered Vehicles Getrag, Type 290 - 5 Speed Manual

Transmission, Overdrive 5th Sped,

Production Option M34

TRANSMISSION RATIOS:

1st 3.553:1

2nd 2.041:1

3rd 1.400:1

4th 1.000:1

5th 0.755:1

Reverse 3.553:1

NUMBER OF TEETH:

Maindrive Input Gear 26

Mainshaft Gear

1st 42

2nd 37

3rd 32

5th 25

Reverse 42

Reverse Idler Gear 23

Cluster Gear Input 33

Cluster Gear

1st/Reverse 15

2nd 23

3rd 29

5th 42

SYNCHROMESH ASSEMBLIES:

Synchromesh Ring Wear

New Clearance - All forward gears 1.35 - 1.95 mm

- Reverse gear 1.00 - 1.40 mm

Replacement Clearance - All forward gears less than 1.35 mm

- Reverse Gear less than 1.00 mm

Synchromesh Ring identification

All forward gears 0058.8.5031.02

Reverse 0058.8.5111.00

END FLOAT CLEARANCES:

Cluster Gear 0.12 - 0.22 mm

SELECTIVE SNAP RING THICKNESSES:

3rd/4th Synchromesh Assembly 1.80, 1.85, 1.90, 1.95, 2.00 mm

2nd Gear Bearing/Thrust Sleeve 2.00. 2.05, 2.10, 2.15, 2.20, 2.25, 2.30 mm

5th/Reverse Synchromesh Assembly 2.00, 2.05, 2.10, 2.15, 2.20 mm

Rear Mainshaft Bearing 2.00, 2.10, 2.20, 2.30 mm

SELECTIVE SPACER/SHIM WASHER THICKNESSES:

Maindrive Gear Spacer Washer 2.10, 2.20, 2.30, 2.40, 2.50 mm

Maindrive Gear Bearing Spacer Shim 0.30, 0.40, 0.50 mm

Cluster Gear End Float Shim 0.30, 0.40, 0.50, 2.30, 2.35,

2.40, 2.45, 2.50 mm

LUBRICANT:

Type 80W Gear Oil to Holden’s

Specification HN 1855 such as

Castrol VMX 80W or equivalent

Capacity (Nominal) 1.8 litres

SEALANTS:

Thread Sealant in nominated locations Loctite 242 or 243 or equivalent to

Holden’s Specification HN1256

Transmission Case Mating Surfaces, Clutch

Throwout Guide Sleeve to Front Case and

other nominated locations Loctite 574 or equivalent, to

Holden’s Specification HN2216

7. TORQUE WRENCH SPECIFI CATIONS

Transmission Filler Plug 25

Transmission Drain Plug 40 - 60

Back-up Lamp Switch 20

Speed Sensor to Bracket Screw 6 - 14

Speed Sensor Bracket to Transmission Housing Bolt 15 - 20

Gearshift Ball Socket Retainer Plate Nuts 6 - 14

Gearshift Lever Brace Mounting Plate Nuts 6 - 14

Gearshift Lever Brace Rubber Mounting to Underbody Bolt 6 - 14

Rear Gearshift Linkage Rubber Mounting to Brace Nut 22

Centre Bearing Carrier to Underbody Reinforcement Bolt 20 - 25

Propeller Shaft Rear Universal Joint to Pinion Flange Bolt 55 - 65

Rear Crossmember to Rear Mounting Attaching Nut 20 - 30

Rear Crossmember to Side Frame Member Bolt 50 - 65

Clutch Housing to Engine Block 30 - 45

Flywheel Lower Cover Plate Screw 5 - 10

Clutch Actuating Cylinder Retaining Nut 22

Rear Mainshaft Bearing Retaining Plate Bolt 20

Shift Detent Spring Cover Bolt 10

Locking Lever Screw Plug 60

Gearshift Selector Rod Bush Lock Bolt 25

Transmission Rear Case Attaching Bolt 25

Reverse Idler Gear Shaft Locating Bolt 25

Shift Detent Spring Cover Bolt 10

Throwout Bearing Guide Assembly Bolt 10

Reverse Block, Retaining Bolt 10

Gearshift Brace to Transmission Rear Case Bolt 15 - 35

Rear Transmission Case Adaptor Plate Bolt 95 - 115

Rear Engine Mount to Adaptor Plate Nut 50 - 65

8. SPECIAL TOOLS

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

KM-328-B SLIDE HAMMER PREVIOUSLY RELEASED

FOR SB BARINA AND

CALIBRA VEHICLES.

INCLUDES CUP KM-328-5-A

AND PIN.

KM-328-7-A PULLER LEGS MODIFY AS DETAILED.

KM-328-9 SPACER USED WITH LEGS KM-328-7-A

KM-409-A INSTALLER USED TO INSTALL THE SHIFT

ROD BEARING INTO THE

FRONT TRANSMISSION

HOUSING.

KM-454-A REMOVER/INSTALLER USED TO REMOVE AND

INSTALL CLUSTER GEAR

BEARING CUPS.

KM-461 INSTALLER USED TO ASSEMBLE THE

TWO TRANSMISSION

HOUSINGS ON

REASSEMBLY.

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

AKM-500-3 SLEEVE PREVIOUSLY RELEASED.

KM-556-1A PULLER PART OF PULLER KIT KM-

556-A, PREVIOUSLY

RELEASED FOR SB BARINA

AND CALIBRA

AKM-628-A EXTRACTOR TOOL USED TO REMOVE THE

MAINSHAFT FLANGE AND TO

SEPARATE THE TWO

TRANSMISSION HOUSINGS

ON DISASSEMBLY.

E308 SEAL REMOVER PREVIOUSLY RELEASED.

J-21426 SEAL INSTALLER PREVIOUSLY RELEASED

FOR 4L60-E AUTOMATIC

TRANSMISSION.

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J-22912-01 PRESS PLATES PREVIOUSLY RELEASED

UNDER THIS NUMBER AND

E6673.

J-36515

J36515-10

ASSEMBLY PALLET & ADAPTOR PLATES NEW RELEASE

USED TO PRE-ASSEMBLE

THE GEARTRAIN AND

SELECTOR COMPONENTS,

PRIOR TO ASSEMBLY INTO

THE REAR TRANSMISSION

CASE.

J-36515-15 INPUT SHAFT ADAPTOR NEW RELEASE

J-36515-16 CLUSTER GEAR ADAPTOR PLATE NEW RELEASE

AU-462 SELECTOR MECHANISM LOADING TOOL NEW RELEASE

USED TO PRELOAD THE

SELECTOR ARM, SPRING

AND ASSOCIATED

COMPONENTS FOR

REASSEMBLY INTO THE

REAR TRANSMISSION CASE.