erv1ce 1 g Manual Synchromesh Transmission &Rear Axle TS883
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erv1ce 1 g Manual
Synchromesh Transmission &Rear Axle
TS883
THE COMPLETE SET OF SERVICE TRAINING MANUALS FOR VAUXHALL VICTOR AND VENTORA CONSISTS OF THE FOLLOWING:
Title
FOUR-CYLINDER O.H.C. ENGINE & CLUTCH- Victor
SIX-CYLINDER O.H.V. ENGINE & CLUTCH -Victor & Ventora
SYNCHROMESH TRANSMISSION & REAR AXLE- Victor & Ventora
SUSPENSION, STEERING, BRAKES- Victor & Ventora
ELECTRICAL EQUIPMENT & INSTRUMENTSVictor & Ventora
BODY- Victor & Ventora
LAYCOCK TYPE J OVERDRIVE
POWERGLIDE TRANSMISSION (with Supplement TS 887)
BORG-WARNER TRANSMISSION (with Supplement TS 888)
ALTERNATOR CHARGING SYSTEMS
The information given in this Manual is correct at the time of preparation, but Vauxhall Motors Limited reserves the right to introduce specification changes which may affect this information.
Ref. No.
TS 881
TS 882
TS 883
TS 884
TS 885
TS 886
TS 862
TS 743
TS 806
TS 776
VAUXHALL Service Training Manual
Synchromesh Transmission & Rear Axle -Victor _ & Ventora
VAUXHALL MOTORS LIMITED LUTON ENGLAND
© October 1968 TS 883
CONTENTS
FOREWORD 3
MODEL DESIGNATIONS 4
SPECIFICATIONS 5
RECOMMENDED LUBRICANTS 8
SYNCHROMESH TRANSMISSION 10
PROPELLER SHAFT AND REAR AXLE 45
GENERAL INDEX 67
FOREWORD
Contents. The main subjects dealt with are listed on page 2. An individual contents list is provided on the first page of each section, and a general index is included at the end of the manual.
Supplementary Information. To keep the manual up to date with design changes which affect servicing procedure and specification data, supplements are published from time to time.
Riteway Service Tools. Reference is made in the manual to Riteway tools designed to facilitate service operations. These tools are available from the following sources:
All territories except Continental Europe, Kent-Moore Tools Ltd., Bow Street, Birmingham 1, England.
Continental Europe, Kent-Moore International A.G., Altgasse 6340, Baar-Zug, Switzerland.
3
4
MODEL DESIGNATIONS
*94335 Victor Estate Car 97.5 cu in (1.61itre) O.H.C. engine
*94369 Victor Saloon 97.5 cu in (1.61itre) O.H.C. engine
94535 Victor '2000' Estate Car 120.5 cu in (2 litre) O.H .C. engine
94569 Victor '2000' Saloon 120.5 cu in (2 litre) O.I-1 .C. engine
94635 Victor '3300' Estate Car 201 cu in (3.3 litre O.H.V. engine
94669 Victor '3300' Saloon 201 cu in (3.3 litre) O.H .V. engine
94869 Ventora Saloon 201 cu in (3.3 litre) O.H.V. eng·ne
*720.5 cu in (21itre) O.H.C. engine also available
VEHICLE IDENTIFICATION NUMBER
0 fii".i\ VAUXHALL MOTORS lTD .. f) ~ BS AU 48 1965
The vehicle identification number is stamped on a plate attached to the left-hand front wheelhouse panel, under the bonnet. On early models the pate is attached to the left-hand front door pillar.
SPECIFICATIONS
OIL CAPACITIES- NOMINAL
Transmission
Three-speed Four-speed Transmission /overdrive
Rear Axle
Victor and Victor '2000' Ventora and Victor '3300'
Mainshaft
Circlip Thickness
Shim Thickness
TRANSMISSION
First Speed Gear and Sleeve - Four-speed transmission
Sleeve diameter Gear clearance on sleeve
Mainshaft Gears
Mainshaft diameter Gear clearance on shaft
Layshaft Gear
Overall Length
Three-speed Four-speed
Thrust Washer Thickness End Float in Casing
2.1 Imp pints 2.5 Imp pints 3.0 Imp pints
2.5 Imp pints 4.0 Imp pints
0.059/0.061 in 0.062/0.064 in 0.065/0.067 in 0.068/0.070 in 0.071 /0.073 in 0.074/0.076 in 0.077/0.079 in
0.003 in 0.005 in 0.010 in
1.3484/1.3490 in 0.0020/0.0041 in
1.4738/1.4744 in 0.0016/0.0032 in
6.141/6.144 in 7.141/7.144 in 0.0615/0.0635 in 0.0048/0.0177 in
5
6
TRANSMISSION (contd)
Reverse Pinion
Overall Length -Three-speed End Float in Casing- Three-speed Shaft Diameter Pinion Clearance on Shaft
Speedometer Gears - - Except overdrive
Teeth on Driving Gear .
Axle Ratio
10/39 8/33
10/39 8/33
10/39 8/33
10/39 8/33
11/38 11 / 38
Universal Joints
Tyre Size
5.60- 13 5.60- 13 6.2 - 13 6.2 - 13 6.9 - 13 6.9 - 13 165 - 13 165 - 13 6.9 - 13 165 - 13
*See text for housing location
PROPELLER SHAFT
Number of Needle Rollers- Each joint
Sliding Sleeve
Sleeve Diameter Sleeve Clearance in Transmission Rear Cover
Pinion Bearings
Pre-load Victor and Victor '2000' :
New bearings Used bearings
Ventora and Victor '3300' : New bearings Used bearings
Shim Thickness
REAR AXLE
1.492/1.496 in 0.004/0.014 in 0.7790/0.7795 in 0.0025/ 0.0040 in
5
*Teeth on Driven Gear
34
17 18 18 19 17 18 17 18 15 15
1.3735 1.3750 in 0.002 0.005 in
10-15 lb in 8-12 lb in
4-8 lb in 3-5 lb in
0.003 in 0.005 in 0.010 in
Differential and Hypoid Gear
Pinion Shaft Diameter .. Pinion Clearance on Shaft Side Bearings
Pre-load: New bearings Used bearings
Spacer thickness- service Shim thickness- service
Permissible Run-out of Differential Case Flange Permissible Run-out of Hypoid Gear Hypoid Gear and Pinion Back lash
TORQUE WRENCH DATA
Differential Bearing Cap Bolts
Victor and Victor '2000' Ventora and Victor '3300'
Hypoid Gear Bolts
Axle Shaft Bearing Retainer Nuts
Victor and Victor '2000' Ventora and Victor '3300'
Coupling Flange Nut
Victor and Victor ' 2000' Ventora and Victor '3300'
0.6242/ 0.6248 in 0.0027/ 0.0053 in
31b 1 lb 0.100 and 0.101 in 0.003 in 0.001 in maximum 0.002 in maximum 0.006/0.008 in
24 lb ft 38 lb ft
38 lb ft
121bft 20 lb ft
75 lb ft 100 lb ft
7
RECOMMENDED LUBRICANTS- OVERSEAS
SAE Usage Viscosity Specification
Number
Transmission /overdrive
Above 0°C 90 GM 4753-M
Below 0°C 80
Main Drive Pinion Splines
Cross-shaft Bearing- 3-speed gear shift linkage -- GM 4733- M
Universal Joints
Transmission Front Cover Sleeve -- GM 4530-M
Gear Shift Linkage - Except cross-shaft bearing ---GM 4550- M
Rear Axle
Above -18°C 90 GM 4655--M
Below -18°C 80 GM 4654-M
8
RECOMMENDED LUBRICANTS- UNITED KINGDOM
Usage BP Castro I Duckham's Esso Gulf Mobil Petrofina Regent Shell
Transmission/overdrive BP Hypoy Hypoid Esso Multi - Mobilube Fina Multi gear Shell
Gear Oil 90 Gear Oil purpose GX90 Pontonic Lubricant Spirax
SAE90 GP90/ 140 Gear MP 90 90EP
EP Oil90 SAE90
-- -
Main Drive Pinion Splines Ener- Castro lease LB.10 Esso Gulflex Mobi I grease Fina Marfak Retinax
Cross-shaft Bearing - · grease LM Grease Multi- A MP Marson Multi- A 3-speed gear shift linkage L.2 purpose IITL2 purpose 2
Universal Joints Grease H
Transmission Front Cover Ener- Castro lease G.G. Esso Gulfsil Mobilgrease Fina Regent Retinax Sleeve grease MS3 Grease Graphite Grease Special Marson Grease AM
C.3G or or LBM.10 Grease G.G7/8G LM2 904 or Energrease Grease or Esso or Gulflex Molytex
L.21M MP Grease Moly Grease 2 (Moly)
Gear Shift Linkage -Except cross-shaft bearing -- -- Keenol - -- -- -- -- --
Rear Axle BP Thio- Hypoid Esso Multi- Mobilube Fin a Multigear Shell Gear Oil Hypoy FD 90 Gear Oil purpose GX90 Pontonic Lubricant Spirax SAE90 or GP90/ 140 Gear MP 90 90EP
i
EP Hypoy Oil90 SAE90
IMPORTANT: Where an axle is topped up or drained before completing the first 10,000 miles or when new hypoid gears are fitted, use only Castro! Thio-Hypoy FD.
--- ----
(!)
10
SYNCHROMESH TRANSMISSION
REAR COVER SEAL 11
SPEEDOMETER DRIVEN GEAR 12
THREE-SPEED GEAR SHIFT LINKAGE 13
FOUR-SPEED GEAR SHIFT LINKAGE 17
TRANSMISSION 18
The three-speed transmission incorporates synchromesh engagement on all forward speeds. Gear selection is by a lever mounted on the steering column and connected by linkage to the transmission striking lever shaft.
The rear of the main drive pinion is supported by a ball bearing in the front cover and a spigot at the front end engages a bush in the crankshaft.
The mainshaft is supported at the front by needle rollers in the main drive pinion, and by a ball bearing in the rear cover. The mainshaft gears operate direct on copper plated journals.
The synchromesh mechanism incorporates two clutch assemblies splined to the mainshaft. The first speed clutch incorporates the reverse gear.
The layshaft gear is supported at each end by needle rollers on a stationary shaft.
The reverse pinion incorporates two bushes and rotates on a stationary shaft.
Two striking forks are secured to rods located longitudinally in the transmission casing. Mounted transversely below the rods is the striking lever shaft. A striking lever secured to each end of the shaft engages a slot in each striking fork rod.
When the gear shift lever is operated, movement is conveyed to the striking lever shaft. The shaft is moved transversely and a striking lever engages the slot in the appropriate striking fork rod. When the striking lever shaft is rotated the rod and fork then moves the clutch towards the selected gear.
The four-speed transmission is similar in basic design to the three-speed unit_ Gear selection is by a central lever mounted on the rear cover and connected by linkage to the transmission striking lever shaft.
The mainshaft first and second gear is bushed and operates on a sleeve pressed on the mainshaft. The reverse pinion is a sliding gear incorporating a groove in the hub of the gear to take the reverse striking fork mounted in the transmission bottom cover.
The striking lever shaft is longer and extends through the left-hand side of the transmission casing into a reverse stop housing, incorporating a locking ball and spring, bolted to the side of the casing.
When reverse is selected, the shaft is moved transversely beyond the first and second speed position, overcoming the locking ball spring pressure, until the lower end of the third and fourth striking lever engages the reverse shift fork in the bottom cover. Rotary movement of the striking lever then moves the reverse pinion into engagement with the gear on the first and second clutch, and the layshaft gear.
REAR COVER SEAL
Oil leakage from the transmission rear cover is
prevented by a spring-loaded seal. Seal can be
renewed with transmission in car, and can be
driven off with a chisel applied alternately each
side of seal outer casing.
11
A
12
REAR COVER SEAL (contd)
To prevent damaging seal outer casing, use a
tubular drift to install seal, after soaking seal
with oil.
SPEEDOMETER DRIVEN GEAR
54243
SP728 B
The speedometer driven gear and shaft is carried
in a housing attached by two screws to the rear
cover. Oil leakage from the shaft is prevented by
a spr'ng-loaded seal.
T e number of teeth on the driven gear is de
pendant on axle ratio and tyre size.
SP727 c SP729
To ensure a driven gear with the appropriate number of teeth meshes correctly with the driving gear on the mainshaft, the bore of the driven gear housing is offset. The position of the eccentric is identified by a flat on the housing.
For 15 tooth gears flat must be positioned as at 'A', 17 and 18 tooth as at 'B' and 19 as at 'C'.
Housing screws are locked by staking.
Before installing seal ensu re that circu lar spring
is located over inner end of seal.
54261
THREE-SPEED GEAR SHIFT LINKAGE
II
2
Gear selection on the three-speed transmiss ion is by a lever mounted on the steering column, in a housing (2) which is free to move rad ial ly. The inner end of the gear shift lever engages a control tube ( 1) which is keyed to the lever housing, but free to move independently of the housing in an endwise direction. Attached to the lower end of the control tube is a change speed lever ( 1 0).
A selector lever (11) pivots on a bracket at the lower end of the steering column. The upper end of the lever is forked, to engage the boss of the change speed lever.
Mounted between the transmission and the underbody sidemember is a cross-shaft (7), carried in a bushed bracket and coupled to the transmission striking lever shaft (8). A bellcrank lever (3) is mounted on the cross-shaft support bracket, and incorporates a pin (5) which engages in a grooved collar ( 4) on the cross-shaft.
An adjustable rod (9) connects the selector lever on the steering column to the bellcrank lever, and a control rod (6), also adjustable, couples the control tube change speed lever to a lever on the cross-shaft.
13
14
THREE-SPEED GEAR SHIFT LINKAGE (contd)
Up and down movement of the gear shift lever causes endwise movement of the control tube, which in turn operates the bellcrank lever through the selector lever and rod. The bellcrank lever moves the cross-shaft and transmission striking lever shaft in an endwise direction, so that one of the striking levers engages the appropriate striking fork rod.
Radial movement of the gear shift lever causes the cross-shaft and transmission striking lever shaft to rotate, so moving the striking fork into the engaged position.
THREE-SPEED GEAR SHIFT LINKAGE - Adjustment
With gear shift lever in second and third speed
plane, height 'A' of lever should be 3.30 in.
0 1005
To correct gear shift lever height, adjust selector
rod at adjuster 'B'. Lengthening rod will lower
gear shift lever.
When in neutral , rad·a position 'A' of gear shift
lever shou d be 5= above horizontal.
To correct radial position, adjust gear shift control
rod at adjuster 'B'. Lengthening rod will raise
gear shift lever.
\\
THREE-SPEED GEAR SHIFT LINKAGE-· Disassembly and Reassembly
The gear shift lever is retained in its housing by a
spring pin.
Gear shift selector lever can be lifted out of
engagement with lower end of gear shift control
tube after removing pivot bolt (arrowed) and
disconnecting selector rod.
1007
15
16
THREE-SPEED GEAR SHIFT LINKAGE -- Disassembly and Reassembly (contd)
To renew boot ( 1) or bearing (2) in cross-shaft support
bracket, bracket must be removed from car. Bearing
can be pushed out of boot after removing washer (3).
Boot can then be withdrawn from bracket.
887
Lubricate all moving surfaces and pack support bracket bush and boot with recommended lubricant when reassembling linkage.
To prevent pin in bellcrank lever bottoming in
collar on cross-shaft, adjust pin so that dimen-
sion 'A' is 0..50 in.
To prevent gear shift lever vibrating, a plain
washer is installed either side of lever in
housing.
Ensure slipper is located on selector lever before
installing lever on gear shift control tube.
FOUR-SPEED GEAR SHIFT LINKAGE
I i
I
I I ~ -- L
~-~----------'J~ '--------___r---
(/?
~--··-5~11) . --~--V__--' ----
872
Gear selection on the four-speed transmission is by a central lever located on top of an inverted U-shaped carrier ( 1) by a bolt (2). The carrier pivots on bushes pressed into the carrier and bracket (3) bolted to the top of the transmission rear cover. The outer leg of the carrier extends downwards and is connected by a control rod (5) to the transmission striking lever shaft coupling (6). The spherical end of the gear shift lever engages the carrier bracket pivot shaft (4) and is loaded by a spring and pad through the centre of the shaft. A selector bar (7), pivots on a fulcrum bracket (8) integral with the transmission casing, and connects the carrier bracket shaft to the transmission striking lever shaft coupling.
Sideways movement of the gear shift lever causes the selector bar to pivot on its fulcrum bracket, so that the transmission striking lever shaft moves transversely, bringing one of the striking levers into engagement with the appropriate striking fork rod.
Forward or rearward movement of the gear shift lever causes the transmission striking lever shaft to rotate, so moving the striking fork into the engaged position.
17
18
FOUR-SPEED GEAR SHIFT LINKAGE (contd)
Gear shift lever carrier bolts ( 1) are accessible
from inside car. After removing bolts and dis
connecting selector bar and control rod from
carrier, gear shift lever together with carrier,
can be removed. Note spacer (2) between
carrier and transmission rear cover.
To ensure full engagement of a selected gear,
dimension 'A' on control rod must be 1.35 in.,
and 'B' 8.90 in. between hole centres.
Lubricate all moving surfaces with recommended grease when reassembling linkage.
TRANSMISSION
The transmission assembly is secured to the clutch housing by four bolts, the two lower of which are inside the clutch housing.
The rear of the transmission is supported by a rubber mounting on a detachable crossmember.
TRANSMISSION-· Removal
Where overdrive is fitted, before commencing removal operations, drive the car in third or top gear, engage overdrive then disengage the overdrive with the clutch pedal depressed and leave in this condition ready for removal.
If, prior to removal, the overdrive was disengaged during acceleration the splines in the planet carrier and in the uni-directional clutch may remain torsionally loaded on the transmission mainshaft. This condition will prevent the overdrive being withdrawn from the transmission mainshaft when separating the two units.
After removing propeller shaft from transmission,
insert a spare sliding sleeve yoke in transmission
rear cover to prevent oil loss.
On four-cylinder cars, use Wrench VR2058 to
remove transmission to clutch housing lower
bolts. Access to bolts is through clutch fork slots.
An overdrive unit is removed as an assembly with the transmission.
TRANSMISSION-- Disassembly
The transmission can be completely disassembled
and reassembled when mounted on a shaped
length of steel angle secured in a vice.
19
20
TRANSMISSION- Disassembly (contd)
Where an overdrive is fitted, unit can be with-
drawn off transmission after removing nuts
around overdrive adaptor.
If the transmission and overdrive has been removed frorn the car without the correct procedure of disengagement having been adopted, or if for some reason e car could not be driven, any torsional load that "lay exist on the transmission mainshaft can be re eased by using a grease nipple (1) and adapto plug (2), installed at the pressure tapping po 'nt o t e overdrive, and a high pressure oil gun ~or pressurizing the hydraulic system whilst the so enoid (3 ·s energized.
A grease nipp e adap•or plug can be made from a 3/8- 16 x 3 8 i . bolt suitably drilled and tapped (if the bo sed ·s too long, the threads of the solenoid co Ia be damaged); the copper washer from t e p ess re tapping point plug should be used o - e adaptor.
two units.
Layshaft must be driven out from rear to front.
Rotate cover or o erdrive adaptor to expose rear
of shaft.
Striking levers are secured to shaft by spring pins.
To ensure pins clear striking fork rods when
being removed, position shaft so that a striking
lever engages slot in a fork rod then drive out pin
in striking lever on opposite end of shaft suffic
iently to release lever from shaft.
On four-speed transmission, before withdrawing
striking lever shaft, remove reverse baulk locking
ball and spring housing.
On three-speed transmission, striking levers and shaft are matched assemblies. To enable levers to be reassembled to their respective ends of shaft, mark levers and shaft with a spot of paint before withdrawing shaft.
Drive out striking fork retaining pins only suffic-
iently to release forks on rods. If pins are driven
out completely they may jam on transmission
casing.
On three-speed transmission, engage reverse gear
so as to support rear end of fork rod when driving
out pin.
21
Z8547
22
TRANSMISSION- Disassembly (contd)
S2510
Striking fork rod locking balls and springs are
retained in transmission casing by a screw at
each side of casing.
After rotating rear cover or overdrive adaptor to
gain access to rear of fork rods, rods can be
driven out from rear to front.
On three-speed transmission, reverse pinion must
be removed before mainshaft can be withdrawn.
Use Remover Z8547 to withdraw pinion shaft.
To remove main drive pinion and bearing from
cover, expand circlip in cover and withdraw
pinion and bearing by tapping end of shaft on
lead block.
Mainshaft can be pressed out of rear cover or
overdrive adaptor after releasing bearing circl ip,
and removing speedometer driven gear housing
from rear cover. Bearing is an interference fit
in cover. To assist removal warm cover adjacent
to bearing.
To ensure that a clutch is reassembled in the correct radial position relative to its hub, mark both parts with a spot of paint before removing clutch.
To press off clutch hub from spigot end of main-
shaft, support adjacent gear on press. Clutch hub
is secured by a circlip.
23
24
TRANSMISSION- Disassembly (contd)
After removing mainshaft rear bearing circlip,
mainshaft can be pressed out of bearing and
clutch hub.
On three-speed transmission, support front face
of first gear on press, and on four-speed trans-
mission, support front face of second gear.
Access to reverse shift fork and striking fork
retaining pins on four-speed transmission, is
through drain plug hole in bottom cover.
When driving retaining pin out of striking fork,
support end of rod. Remove striking fork rod
locking ball and spring before driving out rod.
TRANSMISSION- Inspection and Reconditioning
Clutches and hubs, and striking forks and rods, are matched assemblies, therefore parts incorporated in either assembly must not be renewed individually.
It is not practical to renew reverse pinion bushes, or first speed gear bush on four-speed transmission, as specialized equipment is needed to size bushes. If bushes are worn a complete assembly must be installed.
Use Z8186 to remove or install rear cover bush,
after removing oil seal. Bush should be installed
so that its outer end is flush with bottom of
chamfer in cover.
Before installing seal, saturate felt seal with oil.
A 'keystone' contour (arrowed) is incorporated
at each end of the clutch internal splines of both
clutches on four-speed transmission and the
second and third clutch on three-speed trans
mission.
A similar keystone contour is also incorporated
at the front end of the internal splines of the
first speed clutch on three-speed transmission.
t Z8186
$2511
52512
25
26
TRANSMISSION - Inspection and Reconditioning (contd)
These contours engage with a similar contour formed in the engagement teeth of the corresponding mainshaft gears and main drive pinion.
The keystone contour provides anti-jump-out characteristics and must not be mistaken for localized wear.
On three-speed transmission, external splines on
first speed clutch and reverse gear hub are stepped
on reverse drive side. Extent of stepped part is
indicated by white lines. This provides anti-jump-
out characteristics when reverse is engaged.
Stepped part must not be mistaken for localized
wear.
Ensure sliding key retainer plate (arrowed) is sec-
s219o urely attached to hub.
54262
Good synchromesh operation will depend largely
on condition of synchronizing ring. Mis-shapen
teeth will create baulking trouble. Rocking of
ring on gear cone indicates ovality in either ring
or cone, or both, resulting in insufficient grip.
Wear on rings or gear cones can be assessed by
comparing frictional grip and relative location of
ring on cone with new components.
THREE-SPEED MAINSHAFT- Reassembly
Sliding key spring with two turned-out ends, must
be assembled to groove in first speed clutch hub.
28
THREE-SPEED MAINSHAFT- Reassembly (contd)
54250
Pips on sliding keys of first speed clutch hub are
centrally disposed and one key is slotted. Spring
with two turned-out ends must be positioned so
that one end is located on slotted key.
Sliding key spring with one turned-out end must
be located in front of first speed clutch hub so
that turned-out end is positioned in slotted key
and in an anti-clockwise direction as viewed from
front of hub.
On second and third clutch hub, pips on sliding
keys are offset and one key is slotted. Keys
must be ·nsta lled ith offset to spigoted end of
hub.
Locate key springs in second and third clutch hub
so that turned-out end of springs is engaged in
slotted key and assembled in an anti-clockwise
direction as viewed from either side of hub.
First speed clutch and reverse gear hub ( 1) must
be assembled to mainshaft with sliding key re
taining plate to rear.
Synchronizing ring (2) must be located so that
sliding keys in hub engage slots in ring.
Assemble first speed gear (3) with cone side to
synchronizing ring.
Longitudinal location of mainshaft is controlled
by mainshaft bearing. To ensure bearing is
correctly located on shaft, it may be necessary
to interpose shims between rear abutment face
of first speed hub and bearing.
Use Gauge Z8518 to determine amount of clear
ance to be taken up by shims. Three thicknesses
of shims are serviced.
54214
29
32
FOUR-SPEED MAINSHAFT- Reassembly (contd)
54214
54254
Turned-out end of each spring must locate in
slotted key and be assembled to hub in an anti
clockwise direction as viewed from either side
of hub.
Assemble first and second clutch hub to main
shaft with longer boss of hub towards rear of
shaft. Align slots (arrowed) in synchronizing
ring with sliding keys, while pressing shaft into
hub.
When pressing first speed gear sleeve on to main
shaft, ensure sleeve contacts rear abutment face
of first and second clutch hub.
c: 0 'Vi "' E "' c: CIJ .... .....
""0 Cl) Cl)
0.
"' .:... :::l 0 u.
33
34
FOUR-SPEED MAINSHAFT- Reassembly (contd)
Longitudinal location of mainshaft is controlled
by mainshaft bearing. To ensure bearing is cor
rectly located on shaft it may be necessary to
interpose shims between first speed gear thrust
washer and bearing.
To assess thickness of shims required, assemble
first and second speed clutch to hub with striking
fork groove to rear of shaft followed by thrust
washer.
Use Gauge Z8518 to determine amount of clear
ance to be taken up by shims. Three thicknesses
of shims are serviced.
When pressing bearing on to mainshaft, ensure
shims are not trapped in circlip groove in main-
shaft. Align slots in synchronizing ring with
sliding keys in clutch hub.
Circlips for mainshaft bearing, third and fourth clutch hub and, speedometer driving gear, are serviced in seven thicknesses.
After locating thrust washer against mainshaft
bearing, select a circlip which is a tight fit in
mainshaft groove.
Speedometer driving gear is installed on main
shaft with chamfered face to front of shaft. To
locate gear in position on shaft select two circlips
which are a tight fit in mainshaft grooves at each
side of gear.
Third and fourth clutch hub must be located on
mainshaft so that longer boss of hub is towards
spigoted end of shaft. Align slots (arrowed) in
synchronizing ring with sliding keys while pres
sing hub on to shaft.
To retain third and fourth clutch hub on main
shaft, select a circlip which is a tight fit in main
shaft groove.
-
54215
35
36
TRANSMISSION -Reassembly
54267
When assembling rear cover over mainshaft, a
spare universal joint sliding sleeve yoke should be
used to prevent damage to rear cover bush.
To assist assembly, warm rear cover or overdrive adaptor adjacent to bearing.
After installing cover or adaptor, ensure bearing
circlip is completely engaged in groove.
Main drive pinion bearing is assembled to pinion
with circlip groove in bearing towards gear.
When assembling pinion and bearing to front
cover, ensure circlip fully engages groove in
bearing.
Needle rollers for main drive pinion are shorter
than rollers for layshaft gear. Retain 24 rollers
in counterbore with petroleum jelly. Do not use
more petroleum jelly than is necessary, other
wise oil drilling will .be choked.
Spacer (arrowed) must be assembled in counter-
4bore after installing rollers.
A spacer is assembled either side of needle rollers
at each end of layshaft gear. 26 rollers support
front of gear and 25 the rear.
On six-cylinder models, rear of layshaft gear is
supported by two rows of 25 rollers with spacer
between each row.
Before installing mainshaft, assemble top speed
clutch to hub so that striking fork groove is
towards front of mainshaft.
54268
~
853
54269
37
38
TRANSMISSION - Reassembly (contd)
After inserting mainshaft in transmission casing, rear cover or overdrive adaptor must be rotated so that reverse pinion shaft can be installed, therefore, do not install cover or adaptor bolts at this stage.
Chamfered end of reverse pinion teeth must face
front of casing. On four-speed transmission,
ensure spacer (arrowed) is located between rear
face of pinion and casing.
Before installing reverse pinion shaft, assemble locking ball to shaft. Drive in shaft f usl, with casing.
On transmissions incorporating overdr"ve, inhib-
itor switch mounting bracket ·s located on
adaptor bolts.
Rear cover, or overdrive adaptor bolts must not be fully tightened at this stage as a pneumatic lock may be created when layshaft is installed.
Ensure slots in top speed synchronizing ring are
aligned with hub sliding keys when installing
main drive pinion.
Top speed striking fork has legs of equal length.
Forks are located on rods so that recessed section
(arrowed) is to front of casing. On three-speed
transmission, engage reverse to support rear of
rod when installing first and reverse fork
retaining pin.
On four-speed transmission, first and second
shift fork is assembled to rod so that jaw of fork
is to front of casing.
Striking fork rod end covers must be installed
open side first, and driven home until they are
flush with front face of casing.
39
A
B
40
TRANSMISSION Reassembly (contd)
1 Before installing striking !ever shaft oil seal,
smear lip of seal with oil. Sea must be driven
fully home, open side first, unf seal contacts
abutment face in casing.
On four-speed transmission, long side of third
and fourth striking lever must be to bottom of
casing, and striking lever shaft located so that
coupling setscrew hole in shaft ·s to '\ards front
of casing.
On left drive three-speed transmission, striking
levers must be located on lever shaft as shown at
'A' and on right drive as at '8'.
On three-speed transmission, locate striking lever
shaft so that yoke is inclined to front of casing
and facing downwards.
On four-speed transmission, ensure 0-ring is
located in counterbore in casing before insta mg
reverse stop housing.
Indented face of layshaft gear thrust washers
must be towards gear.
Position front washer with tab located in slot ·n
casing and rear washer with flat edge paral lel to
bottom face of casing.
54454
41
42
TRANSMISSION- Reassembly (contd)
Before installing layshaft, assemble locking ball
to shaft. Drive in shaft flush with casing.
Ensure rear cover or overdrive adaptor bolts are tightened after installing layshaft.
On four-speed transmission, reverse str iking fork
( 1) must be located on rod in bottom cover with
retaining pin hole offset to front of cover and
shift fork (2) with jaw towards cent re of cover.
Striking fork rod end cove rs are ·nsta ed open
side first.
When install ing bottom cover on four-speed
transmission , ensu re reverse striking fork en
gages groove in reverse pinion.
Ensure speedometer driven gear thrust pad
(arrowed) is located in rear cover before instal-
ling gear and housing.
S4273 -------
A SP728 B SP727 c SP729
The number of teeth on the speedometer drive'1 gear is dependant on axle ratio and tyre size.
To ensure a driven gear with the appropr iate 'lumber of teeth meshes correctly with the driving gear on the mainshaft, the bore of t'le dr;~er gear housing is offset.. The position of the eccentric is identified by a flat on the hous;ng.
For 15 tooth gears flat must be pos:t:oned as at 'A', 17 and 18 tooth as at 'B' and 19 as at 'C'.
Housing screws are locked by staking .
Before installing speedometer driven gear shaft
seal, ensure that circular spring is located over
inner end of seal.
S4261
43
44
TRANSMISSION- Reassembly (contd)
On transmissions incorporating overdrive, pump
eccentric is retained on mainshaft by a circlip.
Before assembling overdrive to transmission,
rotate transmission mainshaft so that peak of
pump eccentric is in the lowest position. This
will assist engagement of pump strap in over-
drive unit.
TRANSMISSION - Installation
To provide initial lubrication for speedometer gears and rear cover bush, inject a small amount of recommended lubricant through end of rear cover.
Lubricate front cover sleeve and main drive pinion splines sparingly with recommended
grease.
Note that parking brake cable is located above engine rear mounting crossmember.
PROPELLER SHAFT AND REAR AXLE
PROPEL LER SHAFT 46
AXLE SHAFTS . . 47
PINION SHAFT SEAL 50
REAR AXLE 52
The rear axle is of the semi-floating hypoid type. The axle used on six-cylinder models is of heavier construction than that of four-cy linder models, but both axles are of similar design.
The differential and hypoid gear assembly, and the hypoid pinion, are carried in the singlepiece axle housing on taper roller bearings. The differential is of the two-pinion type.
The drive to the axle is through a single propeller shaft coupled directly to the transmission mainshaft by a sliding sleeve.
45
46
PROPELLER SHAFT
After removing propeller shaft from transmission,
insert a spare sliding sleeve yoke in transmission
rear cover to prevent oil loss.
PROPELLER SHAFT- Yoke or Journal Renewal
Two makes of propeller shaft are
used, Hardy Spicer and BRD.
Replacement yokes and journal
assemblies are interchangeable.
After removing snap rings from yokes, use
Remover 01093 to partially remove each bearing
race.
Bearing race can be finally removed by clamping
remover and race in a vice and tapping shaft so as
to release bearing from yoke.
Ensure that each bearing race is one-;:ni:-c i111ec
with recommended grease before asse ~
When tapping home bearing races. usc a fla'"-
faced drift slightly sma
bore.
Any excess grease exud·ng fro ; .:ourth
bearing journal, after t f-Jree bea rings il B\' e oeen
installed, shou ld be reiT'ove 'l
bearing is insta ll ed .
AXLE SHAFTS
The axle shafts are supported by a ba bear ing embodying a lip-type oil seal (1), and an oil sea ling r ing 12) in the outer race to prevent oil leakage between bearing and axle housing. On Victor and Victor '2000' sa 'oons, the bearing is retained on the shaft by a pressed-on fl anged ring (3). On estate cars and Ventora and V icto r '3300' a larger diameter bearing is used, and is reta ined on the shaft by a shrunk-on ring.
An oil drain is provided through a channe l form ed in the bearing retainer pl ate and a hole in the brake flange plate.
47
48
AXLE SHAFTS- Removal
Axle shaft bearing retainer plate nuts are acces
sible through holes in shaft flange.
If axle shaft bearing is tight in housing, use a slide
hammer and adaptor to release bearing from
housing. Do not use levers, as this may distort
brake flange plate.
AXLE SHAFTS-· Bearing Renewal
Before pressing shaft out of bearing, loosen
bearing retainer r"ng by nicking ring with a chisel.
Use Plate Z8461 and Adaptor Z8475 to support
bearing on press. Adaptor is not required on
estate cars and Ventora and Victor '3300'.
New bearing must be pressed on to shaft .vith
sealing ring groove in outer race towards so lined
end of shaft.
On Victor and Victor '2000' saloons,
Z8553 to press bearing retainer ring, + ar.gec s1ce
first, into position on shaft. Retaine· •
be installed cold.
On estate cars and Ventora and V i c~o r ' 33''"
heat retainer ring to dark blue co o .. m:~ · ~
installation. Slide a heavy weight over sit =~~
maintain ring in contact with bear·ng ar.c l::ave
in position until ring has cooled.
AXLE SHAFTS- Wheel Bolt Renewal
Use Installer Z8446 as shown to press bolt · nto
flange, then invert installer and peen bolt shou l
der into recess in flange to secure bolt.
54473
49
50
AXLE SHAFTS- Installation
Before installing shaft, ensure cut-away in bear-
ing retainer plate gasket is in line with drain hole.
Smear axle shaft with oil, before installing, to
prevent rust. Ensure that sealing ring (arrowed)
is located in bearing groove, and smear sealing
ring and axle housing bore with oil to facilitate
entry of ring.
Tighten bearing retainer plate nuts to specified
torque.
PINION SHAFT SEAL
Oil leakage from the pinion shaft is prevented by a spring-loaded seal. Seal can be renewed with axle in car.
Use Holding Bar 28307 when removing coupling
flange nut.
Before removing coupling flange, mark posit ion
of flange relative to pinion shaft to ensure correct
location on reassembly.
Seal can be removed with a centre punch afie~
prising dust shield off pinion shaft.
Before installing seal, smear lip of seal a11d mating A
face of pinion shaft with oil. Seal must be located
in housing, open side first, so that dimens·o- ' A' L ,. a !?iF!
is 0.19 in. on Victor and Victor '2000' and 0.29 in.
on Ventora and Victor '3300'.
885
On Victor and Victor '2000', use Installer VR2053
to install seal. On Ventora and Victor '3300' use
Installer V R 2034.
51
I. __//
52
PINION SHAFT SEAL (contd)
Dust shield must be driven on to pinion shaft un-
til dimension 'A' is 0.36 in. on Victor and Victor
'2000' and 0.62 in. on Ventora and Victor '3300'.
Tighten coupling flange nut to specified torque. Support flange when staking nut.
REAR AXLE
The rear axle is coupled to the underbody members by two upper ( 1) and two lower (2) longitudinal arms bolted to the axle housing. In addition a Panhard rod (3) is connected between the axle housing and body members to prov ide lateral stability.
REAR AXLE- Removal
For axle removal, car must be supported on
stands located on underbody, forward of o\·:er
suspension arms. After removing prope ler
shaft, insert a spare sliding sleeve yoke i
mission rear cover to prevent oil loss.
EAR AXLE- Disassembly
Right-hand bearing cap and housmf c:qacem to
cap are marked to ensure caps are
changed during reassembly.
Use Holding Bar Z8307 when removing coup ling
flange nut.
~
53
54
REAR AXLE- Disassembly (contd)
Before removing flange, mark position of flange
relative to pinion shaft, to ensure correct location
on reassembly.
Oil sea l can be removed with a centre punch after
prising dust shield off pinion shaft.
The hypoid pinion bear ings are reta ined in the
axle housing by a nut whi ch is staked into the
pinion shaft.
To remove nut use Wrench Z8534 for Victor
and Victor '2000' wh il e holding coupling flange
with Holding Bar Z8307. For Ventora and
Victor '3300' use Wrench Z8421.
Pinion can be tapped out from front of housing. Compressible spacer on pinion shaft is of no further use and must be discarded.
Use Removal Plate Z8533 on Ventora and Victor
'3300', when pressing pinion out of rear bear ·ng
inner race. On Victor and Victor '2000' use
Removal Plate Z8519.
Use the following service tools wi th :-:ai'd e D 1179
to remove pinion bearing outer races:
Victor and Victor '2000' Ventora and Victor '3300'
Z8546- Front Z8422- f ront
Z8435- Rear Z8441 - '-(ear
Pinion shaft can be driven out of differential case
from dowel end after removing hypoid gear.
813
55
J
56
REAR AXLE - Inspection and Reconditioning
Use Ram JWP40 with Legs and Plug Z8390 to
remove a differential bearing. When installing
new bearing make sure it is right home against
spigot shoulder.
Ensure that breather is clean and that breather
cap can be rotated freely.
REAR AXLE- Reassembly
$4285
A pair of guide studs sere ed into hypoid gear
will ensure correct ocat'on of gear on differential
case. To facilitate ·nstallation, warm gear evenly
before placing ·n position. Use new lockwashers
under bolt heads and tighten bolts to specified
torque.
L9
58
REAR AXLE - Reassembly (contd)
In production built axles, lateral location of the differential, and bearing pre-load, are controlled by spacers installed behind the bearings. The spacers range in thickness from 0.200 to 0.243 in.
For service, spacers 0.100 and 0.101 in. thick, and shims 0.003 in. thick are available. With a combination of two service spacers and a varying number of shims, the entire range of production spacers can be covered in steps of 0.001 in.
Spacers and shims must be selected, and bearing pre-load checked, before installing pinion. To make a preliminary assessment of spacer and shim thickness required, proceed as follows:
(a) Assemble differential and bearings to axle housing and place two service spacers between each bearing and housing.
(b) Insert an equal number of shims between each pair of spacers to eliminate and float in bearings.
(c) Remove differential and add a shim to one of the spacer and shim packs.
To facilitate assembly prior to checking bearing
pre-load, place selected spacers and shims in axle
housing before installing differential and bearings.
Before checking bearing pre-load, tighten bearing cap bolts to specified torque, and at the same time lightly tap bearing caps and rotate differential to settle bearings.
To check side bearing pre-load, use a spring
balance in conjunction with a length of twine
wound around differential case flange. Specified
pre-load must be obtained by adding or remou-
ing shims, or changing spacer thickness.
Specified torque must be applied to bearing cap
bolts before each pre-load check is carried out.
Run-out of hypoid gear should be checked afte
correct bearing pre-load has been obtainec.
run-out is in excess of specified figure, gear must
be removed from differential and a chec
for foreign matter on mating faces, or a cnec
made for run-out of differential case f'ange.
After removing differential on complet ion of run-out check, selected spacers and shims must be retained in a safe place for final assembly.
Always renew compressible spacer (1 ), pinion
bearing nut (2), oil seal (3), dust shield (4) and
flange nut (5) when reassembling pinion.
5
I 0
• 3 ~ I 1
~ s 3279
59
60
REAR AXLE -Reassembly (contd)
871
Correct endwise location of the pinion, relative
to the hypoid gear, is obtained by shims inter
posed between the pinion rear bearing and the
bearing abutment face in the axle housing.
Shims must be calculated to compensate for the
manufacturing tolerances of the pinion bearing,
pinion and axle housing. Shims are serviced in
three thicknesses.
The three controlling factors which together determine total thickness of shims required are as follows:
Item 1 - - Actual thickness of pinion rear bearing~
To measure bearing, mount on Jig Z8391 and
settle bearing by pressing down on outer race
while rotating it in each direction. Measure bear
ing and jig plate at two opposite points, and
subtract jig plate thickness to obtain actual bear
ing thickness. To obtain shim correction for
bearing, subtract actual bearing thickness from
theoretical thickness which is 1.1643 in. on
Ventora and Victor '3300' or 0.9626 in . on
Victor and Victor '2000'.
Where bearing thickness is same as theoretical
thickness no shim correction is necessary.
Item 2- Depth of pin ion rear bearing abutment
face in axle housing.
Shim correction necessary to compensate for any
deviation from designed depth of bearing abut-
ment face is stamped in thousandths of an inch on
axle housing rear face. Where marking on housing
is '0', no correction is necessary.
Item 3 -- Pinion meshing correction.
Shim correction necessary to correct pinion-to-
hypoid gear mesh setting is etched in thousandths
of an inch on pinion. Where marking is '0 ' no
correction is required.
54290
Example of Sr''Tl Calcula··
· '"' ickness .
'less
Add ax le housi
Add pinion mesnin:::
Total calculated th ickness of sh·ms required is
1.1643 in *
1.1600 in *
0.0043 in
0.0030 in
0.0050 in
0.0123 in
* For the purpose o1 rnis example a Ventora and Victor '3300' bearing is quoted
Result of calculation should be adjusted to nea rest thousandth of an inch. In above example this results in a final total shim th ickness of 0.012 in.
Before installing pinion rear bearing outer race in
axle housing, install required number of sh ims
equal to total calculated thickness. Check each
shim individually to ensure maximum accuracy.
61
62
REAR AXLE - Reassembly (contd)
Use the following service tools with Handle D 1179
to install pinion bearing outer races:
Victor and Victor '2000' Ventora and Victor '3300'
Z8544 - F rant Z8437 - F rant
Z8437- Rear Z8440- Rear
812
When assembling pinion in axle housing, place
a new compressible spacer over pinion shaft and
while supporting pinion, tap front bearing inner
race into position on shaft, using Installer VR2034
for Ventora and Victor '3300' and VR2053 for
Victor and Victor '2000'.
Before installing pinion bearing nut, smear threads of nut and pinion shaft with oil.
S98 S4288
Pinion bearing nut must be tightened progressively to compress spacer while making frequent checks with Gauge 598, until specified bearing pre-load is obtained. If pre-load limit is exceeded due to overtightening, compressible spacer must be renewed as it will have become over-compressed for use at correct pre-load.
Do not stake nut at this stage, or install pinion shaft seal and dust shield, as it may be necessary to remove pinion later, to adjust bearing shim thickness.
Before installing differential, locate felt pad in
housing, and on Ventora and Victor '3300
ensure magnetic plate is secured to oad retainer
in position shown.
When assembling previously selected sic ::: oearmg .....
spacers and shims in axle housing, numbe
shims between spacers on right-hand sice r.1 .....
exceed those on left-hand side. This v. ·u ensure
initial clearance between pinion and hypo-
gear teeth.
Backlash between hypoid gear and pinion must
be checked at heel of tooth. To obtain spec ified
backlash, shims must be interchanged side for
side. Preliminary backlash checks can be made
without installing bearing caps, but a final check
must be made with caps installed and bolts tight
ened to specified torque.
63
64
REAR AXLE- Reassembly (contd)
Having obtained correct backlash, a gear marking
check must be carried out to ensure hypoid gear
and pinion are correctly meshed. Use Handle
Z8304 to rotate pinion while applying a load on
hypoid gear.
Correct hypoid gear meshing should produce marking 'A'. Marking 'B' indicates that pinion is too far out of engagement with gear, necessitating increased pinion rear bearing shim thickness. If marking is as 'C', pinion must be relocated by decreasing shim thickness.
Where it is necessary to increase total thickness of shims, compressible spacer must be renewed, as it will have become over-compressed for correct pre-load.
Spacer renewal is not necessary when reducing shim thickness as spacer must be compressed further to obtain correct pre-load.
Having obtained correct gear meshing, lock pinion
bearing nut by staking lip of nut into slot in
pinion shaft with Lever VR2067. Do not use a
punch as this may upset bearing pre-load.
To ensure adequate staking, vee-block of lever
should be adjusted so that lower end of lever is
approximately parallel with pinion shaft before
'" applying pressure to nut.
Before installing pinion shaft seal, smear lip of
seal and mating face of shaft with oi . Seal must
be located in housing, open side first, so that
dimension 'A' is 0.19 in. on Victor and Victor
'2000' and 0.29 in. on Ventora and V ictor
'3300'.
Use Installer VR2053 on Victor and
'2000' and Installer VR2034 on Ventora o.
Victor '3300' to install pinion shaft seal.
Dust shield must be driven on pinion until
sion 'A' is 0.36 in. on Victor and Victo~ ' 2
and 0.62 in. on Ventora and Victor '3300'.
Coupling flange nut must be tightened to specified
torque. Before staking nut, support flange on bock
of wood.
;
886
65
66
REAR AXLE - Reassembly (contd)
Before installing axle shaft, ensure cut-away in
bearing retainer plate gasket is in line with drain
hole.
Smear axle shafts with oil, before installing, to
prevent rust. Ensure that sealing ring is located
in bearing groove, and smear sealing ring and axle
housing bore with oil to facilitate entry of ring.
Tighten bearing retainer plate nuts to specified
torque.
REAR AXLE- Installation
Before tightening upper and lower suspension arm bolt nuts, weight of car must rest on axle.
Use only correct grade of oil (see special note under 'Recommended Lubricants') when refilling axle housing.
GENERAL INDEX
A Axle Shafts . . . . .. . . . . . . . . . . 47
D Differential Side Bearing Adjustment .. .. . . . . . . 58
G Gear Shift Linkage- Three-speed 13
Gear Shift Linkage - Four-soeed . 17
L Lubricants Recommendec .. . . . . . . _,, _ . . 8
p
Pinion Shaft Sea l .. 50
Pinion Bearing Adjustrer-i: .. 60
Propeller Shaft .. 46
R Rear Axle . . . . .. 52
Rear Cover Seal - T ransf" ission 11
Recomm~nded Lubricants .. . . 8
s Specifications . . . . 5
Speedometer Driven Gear 12
T Torque Wrench Data 7
Transmission .. 18
u Universal Joints . . .. . . . . . . . . . . 46
w Wheel Bolts . . . . . . . . . . . . . . . . 49
67
VAUXHALL
Training Manual · _ TS973
SUPPLEMENT
Synchromesh Transmission and Rear Axle - FD Victor, VX4/90 and Ventura
. ·-
VAUXHALL MOTORS LTD
LUTON - ENGLAND
- @ February 1971
CONTENTS
AXLE HOUSING SHIM CORRECTION FIGURES 16
AXLE SHAFT BEARING REMOVAL PLATE AND ADAPTOR 14
AXLE SHAFT WHEEL BOLT RENEWAL 14
DIFFERENTIAL PINION SHAFT LUBRICATION 15
FOUR-SPEED GEAR SHIFT LINKAGE 7
FOUR-SPEED TRANSMISSION 11
HYPOID PINION BEARING SPACER 16
HYPOID PINION SHAFT SEAL-Four-cylinder Models (Extended 14 Pinion Shaft)
HYPOID PINION SHAFT SEAL-Four-cylinder Models (Short 15 Pinion Shaft)
PROPELLER SHAFT . . 12
REAR AXLE-Four-cylinder Models 12
REAR AXLE-VX4/90 12
RECOMMENDED LUBRICANTS 5
SPEEDOMETER DRIVEN GEAR 6
TRANSMISSION MAINSHAFT LUBRICATION 11
TRANSMISSION/OVERDRIVE UNIT 01 L LEVEL 12
TRANSMISSION/OVERDRIVE UNIT- VX4/90 11
TRANSMISSION REAR COVER SEAL 6
UNIT IDENTIFICATION 4
VEHICLE IDENTIFICATION . 3
INTRODUCTION
This supplement contains information on changes in design and service procedure since publication of Training Manual TS883 which covers Synchromesh Transmission and Rear Axle on Victor and Ventora. The supplement also covers the transmission and rear axle on VX4/90, Model 94769.
The information given in this supplement is correct at the time of preparation but Vauxhall Motors Ltd reserves the right to introduce specification changes which may affect this inform
ation.
VEHICLE IDENTIFICATION
On later models the vehicle identification plate, bearing the model designation and chassis number, is attached to the instrument panel at the left-hand side and can be read through the windshield glass.
A service parts identification plate is attached to the left-hand front wheelhouse panel, under the bonnet. The plate bears the following information in the sequence shown:
Model Destination Job No Paint Code Trim Code
Option Codes
3
4
UNIT IDENTIFICATION
The transmission has a manufacturing date code stamped on the rear cover.
The rear axle has a manufacturing date code stamped on the housing rear cover.
The rear axle ratio is indicated by a letter stamped on the pinion housing. The interpretation of the letters is:
• I
B-8/33, C-1 0/39, D-11 /38, H-11 /34, J-10/41, K-11/41.
RECOMMENDED LUBRICANTS- United Kingdom
Usage BP Castro I Duck hams Esso Gulf Mobil Petrofina Shell Texaco
Transmission /overdrive BP Gear Castro I Hypoid 90 Esso Gear Multi - Mobilube Pontonic XP Shell Multigear Oil SAE Hypoy Oil GX90/ purpose GX90 SAE90/ 140 Spirax Lubricant 90EP 140 Gear0il90 90EP 90
Transmission Mainshaft Journals Rocol Anti-scuffing Paste
Differential Pinion Shaft Oil Seals
Main Drive Pinion Splines Energrease Castrol LM LB.10 Esso Gulflex A Mobil grease Fin a Retinax A Marfak
Main Drive Pinion L.2 Grease Multi- MP or Marson All
Spigot- Four-cylinder purpose Mo bi I grease HTL2 Purpose Engine Grease H Super
Universal Joints
Gear Shift Linkage Energrease Castrol MS3 C.G. Grease Esso Gulf Mobil grease Fin a Retinax Regent Transmission Front C.3G or or Graphite Graphite Super Marson AM Grease
Cover Sleeve Energrease LBM.10 Grease Grease No. 1 LM2 904 or Clutch Fork Ball L.21M Grease or Esso or Molytex
MP Grease Gulflex Grease 2 (Moly) (Moly)
Rear Axle BP Gear Castro I Hypoid 90 Esso Multi - Mobilube Fina Shell Spirax Universal Oil SAE Thio- Gear Oil purpose GX90 Pontonic XP 90EP Thuban 90 or 90EP Hypoy GX90/ 140 Gear Oil SAE 90/140 Multigear
FD or 90 Lubricant 90 Hypoy
IMPORTANT NOTE: Where an axle is topped up or drained before completing the first 10,000 miles or when new hypoid gears are installed, use only Castrol Thio-Hypoy FD.
'
tn
RECOMMENDED LUBRICANTS- Overseas
Usage SAE Viscosity Number Specification
Transmission/ overdrive Above 0°C 90 GM 4753- M
Below 0°C 80
Transmission Mainshaft Journals Paste of heavy mineral
Differential Pinion Shaft oil with a minimum of --Oil Seals 25% by weight of
molybdenum disulphide
Main Drive Pinion Splines Main Drive Pinion Spigot- -- GM 4733- M Four-cylinder Engine
Universal Joints
Gear Shift Linkage Transmission Front Cover Sleeve -- GM 4530- M Clutch Fork Ball
Rear Axle Above- 18°C 90 GM 4655- M
Below- 18°C 80 GM 4654- M
TRANSMISSION REAR COVER SEAL
The rear cover seal used on later models does not incorporate a felt ring.
Use Installer Z8537 to install seal. Before installing propeller shaft, smear lip of seal with recommended lubricant (not oil) and ensure surface of sliding sleeve is free from burrs and scores.
SPEEDOMETER DRIVEN GEAR The speedometer driven gear data given in the manual is supplemented as follows:
6
Axle Ratio
10/41 11/41 10/41
Tyre Size
5.60- 13 5.60- 13 6.2S- 13
Teeth on Driven Gear
18 16 19
Axle Ratio Tyre Size Teeth on Driven Gear 11/41 1·12- - t 6.2S- 13 17 10/41 i-t. l - ' 6.9S-13 18 11/41 6.9S- 13 16 11/34 6 •0'\ _, 6.9S- 13 14
10/39 5 •4 - 1 6.9S- 13 17 10/41 165SR- 13 18
11/41 165SR- 13 16 11/34 165SR- 13 14 10/39 175/70 HR- 13 18
Where a driven gear having 14 or 16 teeth is used, the housing should be installed with the
flat positioned as for a 15-tooth gear.
FOUR-SPEED GEAR SHIFT LINKAGE
On later models a revised gear shift linkage is used.
The linkage consists of a gear shift upper lever ( 11) pinned to a finger (2) which pivots in an intermediate lever ( 1 ). The intermediate lever pivots on a bush (8) pressed into a carrier bracket (7), which is bolted to the transmission rear cover. The outer leg of the intermediate lever is extended downwards and is connected to the quadrant-shaped striking lever shaft coupling (6) by a cont_rol rod (5). The spherical end of the finger engages in the intermediate lever pivot shaft (10) which runs in the carrier bracket bush, and is loaded by a spring and pad (9) in the centre of the shaft. A selector bar ( 4) engages a grooved adjuster (3) in the lever pivot shaft and connects the pivot shaft to the striking lever shaft coupling. The selector bar pivots on a shouldered bolt attached to a lug on the
9
8
7
11___1
'l_ d jl ~ - 2
' 'I . ~
6
transmission casing. r - 2o33
Forward or rearward movement of the upper lever is transmitted through the intermediate lever to the control rod. Sideways movement of the upper lever is transmitted through the finger and intermediate lever pivot shaft to the selector bar.
7
8
FOUR-SPEED GEARSHIFT LINKAGE (Contd)
2 0~9
Accidental selection of reverse gear is prevented by a stepped abutment (3) in a housing (2) at the lower end of the upper lever contacting a corresponding step (4) on the intermediate lever. To select reverse the abutment is lifted by a cable ( 1) passing through the centre of the gear shift lever and connected to a lift collar at the top of the lever.
Cable renewal necessitates removal of the gear
shift lever assembly.
To withdraw gear shift lever assembly, remove gear shift finger pivot pin (retained by an Eclip). Access to pivot pin is gained by raising gear shift boot. Console is retained by screws, the front two of which are accessible after removal of ash tray on Victor models.
Cable can be disconnected from lift collar by loosening clamp screw (arrowed) after pulling off lever grip.
1
On overdrive models, lever grip includes overdrive switch and grip is threaded to lever shroud. Grip may be unscrewed after prising off top of grip and disconnecting wires from switch.
To withdraw cable from lower end of lever, remove gear shift finger and stepped abutment, both of which are pinned to lever.
The intermediate lever pivot shaft bush is an interference fit in the carrier bracket and is retained by a circlip. If bush requires renewal, it must be pressed out of carrier bracket from selector bar side.
S4963
9
FOUR-SPEED GEAR SHIFT LINKAGE (Contd)
Bush must be installed with cut-away section uppermost and flats parallel to the base of carrier bracket.
On reassembly, smear all working parts with recommended lubricant.
Remove any excessive side clearance in the selector bar pivot by adding special washers between bar and I ug. I nsta II washers with convex side towards lug.
When installing cable, insert the compression spring into lower end of lever before threading cable and connector up the lever.
2226
10
On overdrive models assemble retainer (arrowed) between lift collar spring and wires to prevent spring chafing wires.
•
After assembling gear shift upper lever to intermediate lever, adjust cable length so that clearance 'A' between the underside of abutment and top of intermediate lever is 0.02/0.04 in.
Check that selector bar is fully engaged in groove of adjuster. A set can be introduced in the bar to provide full engagement.
Select first or second gear and set adjuster bolt in lever pivot shaft so that clearance 'B' is 0.012/0.020 in.
$4954
TRANSMISSION/OVERDRIVE UNIT- VX4/90 On VX4/90 a four-speed synchromesh transmission with Laycock Type J overdrive is standard equipment. Service information is the same as given for four-cylinder Victor models.
TRANSMISSION MAINSHAFT LUBRICATION
As the copper plating is deleted from later mainshafts, it is important that an unplated shaft is smeared with recommended lubricant (not oil), before assembling the gears to the shaft.
FOUR-SPEED TRANSMISSION On later transmissions the r~werse stop mechanism is incorporated in the gear shift lever, and the end of the striking lever shaft is sealed by a cover in the casing except when a reverse lamp switch is fitted. When installing switch, assemble an 0-ring to groove in switch body.
Assemble coupling to striking lever shaft so that hole in coupling is towards top of transmission casing.
11
TRANSMISSION/OVERDRIVE UNIT OIL LEVEL
After installing a transmission/overdrive unit it is important that the transmission oil level is checked after operating the overdrive to ensure the oil passages and cylinders are filled. It is not sufficient to run the engine with the transmission in neutral since in this condition the overdrive pump is inoperative.
PROPELLER SHAFT
55882
On some cars the universal joint trunnion bearing races are retained in the yoke by staking, instead of by snap rings.
Where renewal of a universal joint is indicated, a replacement propeller shaft complete with univP.rsal joints must be installed.
REAR AXLE - VX4/90
Service information for the VX4/ 90 rear axle is the same as given for four-cylinder Victor models.
REAR AXLE - Four-cylinder Models
On later four-cylinder models a revised rear axle is used. The axle is similar to earlier units
except that the pinion shaft is shorter and the propeller shaft coupling flange seats directly
against the pinion front bearing inner race . The pinion shaft seal contacts the outside of the
flange sleeve.
12
Service information contained in the manual may be applied to the later axle except where amended by this supplement.
f A
When renewing dust shield, press shield squarely on to coupling flange until dimension 'A' is 0.70 in.
1
.. ,.. _l ·::·:.. -
For removal of pinion front bearing outer race use Remover Z8442 and for installation use Installer Z8506. For installation of pinion front bearing inner race use Installer VR2053.
Hypoid gear and pinion backlash is 0.005/0.007 in.
1066
13
AXLE SHAFT BEARING REMOVAL PLATE AND ADAPTOR
Removal Plate VR2077 and Adaptor VR2079 supersede Z8461 and Z8475 for removal of the axle shaft bearing on four-cylinder saloons.
On six-cylinder models and estate cars use Removal Plate VR2077 and Adaptor VR2078.
AXLE SHAFT WHEEL BOLT RENEWAL
On later models the wheel bolts are not peened into the axle shaft flange, which obviates removal of the axle shaft when renewing a wheel bolt.
To renew bolt, drive out existing bolt and draw in new bolt using a distance tube and wheel retaining nut.
When installing a replacement axle shaft, wheel bolts must be pressed into flange before install
ing shaft.
14
HYPOID PINION SHAFT SEALFour-cylinder Models (Extended Pinion Shaft)
On later four-cylinder models with an extended
hypoid pinion shaft a revised pinion shaft
seal is used. When installing, smear periphery of seal casing with jointing compound and locate seal in axle housing so that dimension 'A' is 0.26 in., to avoid the possibility of a foul with the threads on the pinion shaft. The dust shield must be located so that dimension '8' is 0.42 in.
HYPOID PINION SHAFT SEALFour-cylinder Models (Short Pinion Shaft)
On later axles a short pinion shaft is used and the seal contacts the outside of the flange sleeve.
If pinion shaft seal is to be renewed without completely disassembling rear axle, coupling flange nut must be retained for re-use. This will enable correct pinion bearing pre-load to be restored on reassembly.
Before installing seal, grind a slot away from and similar to existing slot in pinion shaft, to provide a new location for staking nut.
Install seal, open side first, with Installer V R 2053 so that it either contacts shoulder in axle housing or seal case is flush with end of housing, whichever occurs first.
Before installing coupling flange, smear lip of seal and coupling land with recommended lubricant.
Coupling flange nut must be tightened so that original nut staking and pinion shaft slot are aligned. Do not overtighten nut. This alignment is essential to restore correct pinion bearing pre-load.
Support flange when staking nut into new slot ground in pinion shaft.
55575
Dl FFERENTIAL PINION SHAFT LUBRICATION
As the copper plating is deleted from later differential pinion shafts, it is important that an unplated shaft is smeared with recommended lubricant (not oil), before installation.
15
AXLE HOUSING SHIM CORRECTION FIGURES
The shim correction necessary to compensate for any deviation from the designed depth of the pinion rear bearing abutment in the axle housing is marked in thousandths of an inch on the axle housing rear face. Any figures adjacent to the bearing lands should be ignored.
HYPOID PINION BEARING SPACER
On later axles a washer is used between the compressible spacer and the pinion front bearing inner race. To compensate for the washer thickness a shorter spacer, of length 0.577/0.585 in. on four-cylinder models and 0.478/0.486 in. on six-cylinder models, is used. On early axles the length of the spacer is 0.657/0.665 in. (four-cylinder models) and 0.558/0.566 in. (six-cylinder models).
16
Body matter set in 11 point medium Univers, on IBM 72 Selectric Composer
Printed in England
I mprime en Angleterre
ROYDON PRINTERS (LUTON) LTD.
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