clutch OPEL FRONTERA 1998 Workshop Manual

7B–20MANUAL TRANSMISSION
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Legend
(1) Release Bearing and Shift Fork
(2) Clutch Housing
(3) Front Cover
(4) Snap Ring
(5) Snap Ring
(6) 1st and 2nd Switch
(7) Drain Plug
(8) Backup Light Switch
(9) Transmission Case(10) Filler Plug
(11) Gear Control Rod
(12) Reverse Restrict Pin
(13) Oil Receiver Pipe
(14) Transfer Adapter
(15) Plug (6VE1) or Neutral Switch (4JX1)
(16) Gear Control Box
(17) Shift Lever Housing
(18) Oil Seal
(19) Plug

MANUAL TRANSMISSION7B–21
Disassembly
1. Remove the drain plug and filler plug.
1. Remove the drain plug (1) and gasket.
2. Remove the filler plug (2) and gasket.
(6VE1)
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2. Remove the clutch release bearing and shift fork.
1. Remove the clutch release bearing (3) from the
front cover.
2. Remove the split pin (4). Remove the shaft from
the under. Remove the shift fork (5).
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3. Remove the switch.
1. Remove backup light switch (6) and gasket.
2. Remove neutral switch (7) and gasket (4JX1).
3. Remove 1st and 2nd switch (8) and gasket.
(4JX1)
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4. Remove the clutch housing.
1. Remove the 9 bolts.
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7B–22MANUAL TRANSMISSION
2. Using a plastic hammer, carefully tap the clutch
housing.
(6VE1)
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5. Remove gear control box and gasket.
1. Remove the 6 bolts, gear control box and gasket.
(6VE1)
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6. Remove transfer adapter.
1. Using a hexagon wrench, remove the plug (1).
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2. Using a pin punch and hammer, drive out the
slotted spring pin (2).
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MANUAL TRANSMISSION7B–33
4. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the following
parts.
1. 5th gear (1).
2. Mainshaft bearing (2).
3. 1st gear thrust washer (3).
4. 1st gear (4).
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5. Remove following parts from mainshaft.
1. Synchronizer assembly (1).
2. 1st gear thrust washer pin (3).
3. 1st gear needle roller bearing (4).
4. 1st gear bearing spacer (2).
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6. Using 2 screwdrivers and hammer, tap out snap
ring.
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7. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the following
parts.
1. Clutch hub No.1 assembly (1).
2. Synchronizer assembly (2).
3. 2nd gear (3).
4. 2nd gear needle roller bearing (4).
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7B–34MANUAL TRANSMISSION
8. Remove the reverse gear from clutch hub No.1.
9. Remove the 3 inserts and 3 compression springs.
When removing the inserts, push the insert
spring with a screwdriver.
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10. Remove the snap ring.
NOTE: Don’t damage the bearing surface.
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11. Using a press, remove following parts.
1. Clutch hub No.2 assembly (1).
2. 3rd block ring (2).
3. 3rd gear (3).
4. 3rd gear needle roller bearing (4).
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12. Using screwdriver, remove the 2 insert springs,
hub sleeve No.2, clutch hub No.2 and 3 inserts.
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MANUAL TRANSMISSION7B–43
4. Inspect hub sleeve and shift arm.
1st–2nd shift arm
1. Using a vernier caliper, measure center groove of
the 1st–2nd shift arm.
Reference: 5.28 mm (0.208 in)
2. Using a vernier caliper, measure flange of the
reverse gear. Calculate the clearance between
the reverse gear and shift arm.
Reference: Reverse gear flange thickness 5.0
mm. (0.197 in)
Standard: 0.15 – 0.41 mm (0.006 – 0.016 in)
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3rd–4th shift arm
1. Using a vernier caliper, measure tip of the shift
arm thickness.
Reference: 10.0mm (0.39 in)
2. Using a vernier caliper, measure center groove of
the hub sleeve No.2. Calculate the clearance
between the hub sleeve No.2 and shift arm.
Reference: Center groove dimension 10.2 mm
(0.402 in)
Standard: 0.15 – 0.35 mm (0.006 – 0.014 in)
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5. Inspect clutch hub and hub sleeve.
1. Check for wear or damage.
2. Install the hub sleeve to the clutch hub, and check
sliding smoothly.
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6. Inspect gear inside diameter.
1. Using a inside dial indicator, measure the gear
inside diameter.
Gear
Standard Diameter
1st46.015 – 46.040 mm (1.8116 – 1.8126 in)
2nd53.015 – 53.040 mm (2.0872 – 2.0882 in)
3rd44.015 – 44.040 mm (1.7329 – 1.7339 in)

MANUAL TRANSMISSION7B–45
8. Install 3rd gear.
1. Install the 3rd gear needle bearing, 3rd gear and
3rd block ring to the mainshaft.
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9. Install the clutch hub No.2.
1. Install the clutch hub No.2 and hub sleeve No.2.
NOTE: Be careful the direction of the clutch hub No.2, as
shown.
2. Using a screwdriver, install 3 inserts and 2
springs.
NOTE: Position the insert springs so that their end gaps
are not in line.
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3. Using installer 5–8840–2553–0 (J–42797) and a
press, install the clutch nob No.2 and hub sleeve
No.2 to the mainshaft.NOTE:
Align the brock ring slots with the inserts.
Check that the gear rotates smoothly.
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4. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A1.80–1.85mm (0.071–0.073in)
B1.85–1.90mm (0.073–0.075in)
C1.90–1.95mm (0.075–0.077in)
D1.95–2.00mm (0.077–0.079in)
E2.00–2.05mm (0.079–0.081in)
F2.05–2.10mm (0.081–0.083in)
G2.10–2.15mm (0.083–0.085in)
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MANUAL TRANSMISSION7B–47
11. Install the clutch hub No.1.
1. Install the 3 inserts and 3 insert springs to the
clutch hub No.1.
Reference: While pushing the insert spring
with a screwdriver, install the inserts.
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2. Install the clutch hub No.1 to the reverse gear.
NOTE: Check the clutch hub No.1 installing direction, as
shown.
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3. Using installer 5–8840–2554–0 (J–42798) and a
press, install the hub No.1 by retaining the
reverse gear.NOTE:
Align the projection of inner ring with hub No.1 slots.
Check that the gear rotates smoothly.
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4. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A2.30–2.35mm (0.091–0.093in)
B2.35–2.40mm (0.093–0.095in)
C2.40–2.45mm (0.095–0.097in)
D2.45–2.50mm (0.097–0.098in)
E2.50–2.55mm (0.098–0.100in)
F2.55–2.60mm (0.100–0.102in)
G2.60–2.65mm (0.102–0.104in)
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7B–66MANUAL TRANSMISSION
38. Install clutch housing.
1. Install the clutch housing to the transmission
case.
Torque: 36 Nꞏm (3.7 kgꞏm/27 lb ft)
NOTE: Tighten the all bolts evenly.
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39. Install the switches.
1. Install the new gasket to the 1st and 2nd switch.
2. Install the 1st and 2nd switch assembly (8).
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
3. Install the new gasket to the backup light switch.
4. Install the backup light switch assembly (6).
Torque: 44 Nꞏm (4.5 kgꞏm/33 lb ft)
5. Install the new gasket to the neutral switch.
6. Install the neutral switch (7) to the transfer
adapter (4JX1).
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
(4JX1)
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40. Install the clutch release bearing (3) and clutch shift
fork (5).
1. Apply the clutch release grease.
1. Fitting surface of the cylinder push rod.
2. Fitting surface of the release bearing hub.
3. The hole of the fork split pin (4).
2. Apply the clutch release grease.
1. The spline surface of the top gear shaft.
3. Install the clutch shift fork (5).
4. Install the snap pin.
5. Install the clutch release bearing (3) to the clutch
shift fork (5).
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7B–72MANUAL TRANSMISSION
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2550–0
(J–42794)
Gear spline pieace
remover
5–8840–2551–0
(J–42795)
Center bearing remover
5–8840–2560–0
(J–42988)
Attachment
5–8840–2552–0
(J–42796)
Counter gear shaft
center bearing installer
5–8840–2553–0
(J–42797)
Clutch hub (No.2)
installer
5–8840–2554–0
(J–42798)
Clutch hub (No.1)
installer
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2555–0
(J–42799)
Installer
5–8840–2556–0
(J–42800)
Counter gear shaft front
bearing installer
5–8840–2559–0
(J–42904)
Top gear shaft front
bearing installer
5–8840–2557–0
(J–42801)
Front rerainer oil seal
installer
5–8840–2558–0
(J–42802)
Transfer adapter oil seal
installer
5–8840–0007–0
(J–8092)
Driver handle