The steps below are shortened from the Vauxhall TIS pages for the Speedster. The VX220 shares the same engines and most of the car, but check anything unusual against your own car. The TIS pictures and the full wording aren't reproduced, so use the workshop manual if you are doing the job. We haven't seen owners' accounts of this job, so there are no owner tips here.
For taking the shaft out and the gearbox seals see Driveshaft removal and gearbox driveshaft seals, and for the passenger side inner boot see Inner CV boot replacement.
Before installation of 3rd gear synchroniser ring, molybdenum layer on reverse side must be removed (shaded area)
Before installation of 4th gear synchroniser ring, the molybdenum layer on the reverse side must be removed (shaded area)
Gaiter, wheel side
The TIS steps are the same for the Turbo and the NA.
Remove
- Remove relevant drive shaft from vehicle - see “Drive Shaft, Remove and Install”
- Secure drive shaft in soft jaw vice
- Using suitable tool, release 2x clip (Slide folding cover along shaft)
- Remove constant velocity joint from drive shaft
- Use soft head mallet to tap inner bearing race
- Remove, then discard clip from drive shaft
- Remove, then discard folding cover from drive shaft
- Clean all components
Install
- Install new folding cover to drive shaft
- Position new retaining clip for folding cover to drive
- Install constant velocity joint to drive shaft (Install new retaining clip to drive shaft)
- Install folding cover to groove on drive shaft and groove on be constant velocity joint
- Check positioning of folding cover and 2x retaining clip
- Use commercially available pliers
- Install drive shaft to vehicle - see “Drive Shaft, Remove and Install”
Gaiter, gearbox side
The TIS steps are the same for the Turbo and the NA.
Remove
- Remove relevant drive shaft from vehicle - see “Drive Shaft, Remove and Install”
- Secure drive shaft in soft jaw vice
- Using suitable tool, release 2x clip (Slide folding cover along shaft)
- Remove constant velocity joint from drive shaft
- Using suitable tool, remove circlip from outer race of
- Remove 6x ball bearing
- Slide bearing cage clear of inner race
- Use commercially available tool
- Remove bearing inner race and bearing cage from drive shaft
- Remove, then discard folding cover from drive shaft
- Clean all components
Install
- Install new folding cover to drive shaft
- Position new folding cover retaining clip to drive shaft
- Install bearing cage, then inner bearing race to drive shaft (Install new circlip to drive shaft)
- Install 6x ball bearing to inner race and bearing cage
- Install outer race to 6x bearing (Install new circlip to outer race)
- Install folding cover to groove on drive shaft and groove on constant velocity joint
- Check positioning of folding cover and 2x retaining clip
- Use commercially available pliers
- Install drive shafts to vehicle - see “Drive Shaft, Remove and Install, Both Sides
Driveshaft strip and rebuild
NA (Z22SE) only.
Procedure
- Illustration of drive shaft
- Remove drive shaft from transmission - see "Drive Shaft, Remove and Install"
- Remove thrust washer and radial needle bearing
- Remove 4th gear, needle bearing, and 4th gear synchroniser ring from drive shaft
- Remove shift sleeve from synchromesh body
- Check all parts for damage, replace damaged parts as necessary
- Press bushing and 3rd/4th gear synchromesh body assembly, 3rd gear synchroniser ring, thrust washer, radial needle bearing, and 3rd gear from drive shaft using KM-6220 and KM-6222
- Check all parts for damage; replace damaged parts as necessary
- Carefully spread needle roller bearings (2, 3), then remove from drive shaft in lateral direction
- Remove radial needle bearing from drive shaft
- Check all parts for damage; replace damaged parts as necessary
- Install radial needle bearing to drive shaft
- Carefully spread needle roller bearings (2, 3), then install onto drive shaft in lateral direction
- Sand down molybdenum layer on reverse side of 3rd gear synchroniser ring using fine grained sandpaper on smooth surface
- Install 3rd gear to main shaft
- Ensure that needle roller bearings (1, 2) are not damaged
- Install radial needle bearing to 3rd gear (Check for proper seating)
- Install thrust washer to 3rd gear (Check for proper seating)
- Install 3rd gear synchroniser ring to 3rd gear Note: More recent transmissions as well as repair kits for 3rd/4th gear synchroniser ring contain wave springs (arrowed)
- Install 3rd/4th gear synchromesh body for 1st/2nd to drive shaft
- Press bushing onto drive shaft using KM-6219
- Ensure that fluid bores coincide and guide (arrow I) of
- Assemble synchromesh
- Spring
- Clamp drive shaft in vice - use protective jaws. Slide
- Push slider slightly upwards. Press ball against spring
- Sand down molybdenum layer on reverse side of 4th gear synchroniser ring using fine grained sandpaper on smooth surface
- Attach 4th gear synchroniser ring and needle roller bearing to synchromesh body Note: Observe installed position
- Install 4th gear with radial needle bearing, radial roller bearing and thrust washer to drive shaft
- Ensure that needle roller bearings and radial needle bearings
- Install drive shaft to transmission - see "Drive Shaft, Remove and Install"