Subject:
Modification of synchronisation for 3rd, 4th and 5th gear in manual transmissions F25 / F35
Vehicles:
Vectra-B with manual transmission F25:
Up to transmission number M 24982 for 5th gear synchronisation
Up to transmission number M 67217 for 3rd and 4th gear synchronisation
Sintra with manual transmission F25 / F35:
Up to transmission number M 00269 for 3rd and 4th gear synchronisation
Up to transmission number M 54294 for 5th gear synchronisation
Note:
| The transmission numbers (serial numbers) are marked horizontally on the identification plates on top of the clutch housing for transmission F25 and F35 (see illustration J 0135). | |||
|---|---|---|---|
| .P. J0135.tif | 9 | 7,5 | tiff;; |
Condition:
In certain vehicles, clattering or slight rattling noises may be produced by the non-utilised 3rd, 4th or 5th gear synchroniser rings in the case of gentle acceleration under load in the engine speed range of 800 to 1200 rpm.
Additional ”sheet metal strips” (1) have been fitted between the synchroniser rings and the synchromesh bodies for the 3rd, 4th and 5th gear synchronisation in the transmissions mentioned.
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Caution! |
|---|---|---|---|
| Sheet metal strips must not be used as of transmission numbers M 24983 for 5th gear synchronisation and M 67218 for 3rd and 4th gear synchronisation (Vectra-B) / M 00270 for 3rd and 4th gear synchronisation and M 54295 for 5th gear synchronisation (Sintra), as the shift sleeves have been modified accordingly for these transmissions. | |||
| .P. J0138.tif | 9 | 7,5 | tiff;; |
Remedy:
The appropriate synchronisation components with additional ”sheet metal strips” are available for the designated transmissions from Service Parts. This entails minimal changes to installation and the installation sequence.
The respective installation position of the sheet metal strips between the synchromesh body and the corresponding synchroniser ring is described below.
Further information concerning the operations ”Drive Shaft, Disassemble and Assemble” and ”5th Gear Synchroniser Unit, Disassemble and Assemble” can be found in the Service Instructions for Vectra B, group ”K”.
Modified installation sequence for 5th gear synchronisation, F25 and F35 transmissions
1 Shift sleeve
2 Synchromesh body
3 Sheet metal strips
4 Synchroniser ring
5 Engaged 5th gear
6 Needle bearing
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Caution! |
|---|---|---|---|
| It must be ensured that the three sheet metal strips do not become displaced during assembly. This can be prevented by clamping the synchroniser ring (4) to the synchromesh body (2) with two rubber bands, as shown in the illustration. | |||
| .P. J0136.tif | 12 | 12 | tiff;; |
Modified installation sequence for 3rd and 4th gear synchronisation, F25 and F35 transmissions
1 Bearing assembly
2 Drive shaft
3 3rd gear needle bearing
4 Engaged 3rd gear
5 Synchroniser ring
6 Sheet metal strips
7 Synchromesh body
8 Retaining ring
9 Shift sleeve
10 4th gear needle bearing
11 Sheet metal strips
12 Synchroniser ring
13 Engaged 4th gear
14 Bearing assembly
| 15 Retaining ring | |||
|---|---|---|---|
| .P. J0137.tif | 12 | 12 | tiff;; |
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Caution! |
It must be ensured that the three sheet metal strips do not become displaced during assembly.
Note:
It should be noted that in the event of repair work to the synchronisation, two different versions may be installed - see Vehicles, page 1.
Both part versions are available from ”Service Parts”.
The individual components of the versions are not interchangeable. It is therefore essential that the instructions in this Technical Information Bulletin are observed.
General:
During the operations, observe the safety measures in the Service Instructions.
These descriptions will be incorporated into the next editions of the Service Instructions.
Parts:
Vectra-B with transmission F25
| Description | Number | Part No. | Catalogue No. |
|---|---|---|---|
| 3rd and 4th gear up to transmission number M 67217 | |||
| Synchronisation kit | 1 | 90 511 263 | 7 18 412 |
| Individual sheet metal strips | 6 | 90 512 204 | 57 18 703 |
| 3rd and 4th gear as of transmission number M 67218 | |||
| Synchronisation kit | 1 | 90 543 240 | 57 18 021 |
| 5th gear up to transmission number M 24982 | |||
| Synchroniser ring | 1 | 90 511 080 | 7 20 715 |
| Individual sheet metal strips | 3 | 90 512 206 | 57 18 702 |
| Synchromesh body | 1 | 90 486 183 | 7 18 458 |
| 5th gear as of transmission number M 24983 | |||
| Synchroniser ring | 1 | 911 777 8 | 57 18 952 |
| Synchromesh body | 1 | 911 777 9 | 57 18 953 |
Sintra with transmission F25 / F35
| Description | Number | Part No. | Catalogue No. |
|---|---|---|---|
| 3rd and 4th gear up to transmission number M 00269 | |||
| Synchronisation kit | 1 | 90 511 263 | 7 18 412 |
| Individual sheet metal strips | 6 | 90 512 204 | 57 18 703 |
| 3rd and 4th gear as of transmission number M 00270 | |||
| Synchronisation kit | 1 | 90 543 240 | 57 18 021 |
| 5th gear up to transmission number M 54294 | |||
| Synchroniser ring | 1 | 90 511 080 | 7 20 715 |
| Individual sheet metal strips | 3 | 90 512 206 | 57 18 702 |
| 5th gear up to transmission number M 54295 | |||
| Synchromesh body | 1 | 90 486 183 | 7 18 458 |
| 5th gear as of transmission number M 54295 | |||
| Synchroniser ring | 1 | 911 777 8 | 57 18 952 |
| 5th gear as of transmission number M 54296 | |||
| Synchromesh body | 1 | 911 777 9 | 57 18 953 |
The transmission fluid below must be used to install rotating transmission components and top up fluid level in transmissions F25 and F35.
| Description | Number | Part No. | Catalogue No. |
|---|---|---|---|
| Transmission fluid | as required | 90 540 998 | 19 40 764 |
Time allowances:
The time allowances remain unchanged and can be found in the current editions of the Labour Time Guide.