OPEL FRONTERA 1998 Workshop Manual

MANUAL TRANSMISSION7B–53
2. Using 2 bolts, install reverse shift arm bracket.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
226RW054
3. Install reverse shift arm No.2 to the reverse shift
arm No.1. Using screwdriver and a hammer,
install the new E-ring.
226RW138
4. Install reverse shift arm No.2 to the reverse shift
arm bracket.
226RW012
20. Install the reverse shift rod.
1. Install the reverse shift arm No.1 compression
spring and ball to the reverse shift arm No.1.
226RW125

7B–54MANUAL TRANSMISSION
2. Install the reverse shift rod from the rear side by
pushing the ball on using a screwdriver.
226RW126
21. Install the reverse-5th shift rod.
1. Install the reverse shift arm No.1 lock ball to the
reverse shift arm No.1.
2. Install the interlock pin to the intermediate plate.
226RW039
3. Put in the reverse-5th shift rod from the front.
226RW011
4. Using a screwdriver and a hammer, install the 2
new shift rod snap rings to the 5th-reverse shift
rod and reverse shift rod.
226RW037

MANUAL TRANSMISSION7B–55
22. Install 1st–2nd shift rod.
1. Install the interlock pin to the intermediate plate.
226RW042
2. Put in the 1st–2nd shift rod from the rear.
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23. Install 3rd–4th shift rod.
1. Install the straight pin and interlock pin to the
intermediate plate.
226RW043
2. Put in the 3rd–4th shift rod from the rear.
226RW046

7B–56MANUAL TRANSMISSION
24. Install the interlock parts.
1. Using a screwdriver and hammer, 2 new shift rod
snap rings to the 1st–2nd and 3rd–4th shift rod.
226RW051
2. Install the 3 shift detent ball and springs to the
intermediate plate.
226RW049
3. Clean up the plug hole.
4. Apply sealant to the plug threads.
sealant: THREE BOND 1344 or equivalent5. Using a torx socket wrench(T40), install and
torque the 4 plugs.
Torque: 19 Nꞏm (1.9 kgꞏm/14 lb ft)
226RW050
25. Install mainshaft assembly.
NOTE: Coat all parts with gear oil before installing them.
1. Using a plastic hammer, tap the 5th-reverse shift
rod at the reverse shift.
226RW180

MANUAL TRANSMISSION7B–57
2. Install the shift arm No.1 and No.2 to the
mainshaft.
226RW010
3. Using a plastic hammer, tap the intermediate
plate and install the mainshaft. Through the shift
arm No.1 and No.2 to the shift rod.
226RW009
4. Using a snap ring expander, install the snap ring.
226RW035
5. Using a plastic hammer, tap the 5th-reverse shift
rod at the neutral shift.
226RW008

7B–58MANUAL TRANSMISSION
26. Install the top gear shaft.
1. Align the projection of the hub No.2 with the
synchronizer ring slots, and install the top gear
shaft assembly to the mainshaft.
2. Check that the gear rotates smoothly.
226RW006
27. Install the counter gear shaft.
1. Temporarily install the counter gear shaft to the
intermediate plate.
226RW028
2. Using installer 5–8840–2552–0 (J–42796) and a
hammer, drive in the center bearing as shown.
NOTE: Outer race snap ring groove toward rear.
226RW192Reference: Drive in the counter rear bearing
by tapping on the front end of the counter
shaft.
226RW022

MANUAL TRANSMISSION7B–59
28. Install the reverse idle gear.
1. Install the reverse idle gear and reverse idle gear
shaft.
NOTE:
Insert the reverse idle gear shaft with the slot toward
rear.
Install the reverse idle gear with the reverse shift arm
No.2.
226RW019
29. Install the bearing plate.
1. Align the bearing plate to groove of the reverse
idle gear shaft.
Torque: 13 Nꞏm (1.3 kgꞏm/113 lb in)
226RW016
30. Install the 5th gear thrust washer.
1. Install the 5th gear thrust washer pin to the
counter gear shaft.
2. Install the 5th gear thrust washer to the counter
gear shaft.
NOTE: Thrust washer must be assembled with the
chamfered face of the washer toward the front.
226RW185
31. Install the counter 5th gear.
1. Install the 3 inserts and 3 compression springs to
the reverse block ring.
Reference: Push the 3 inserts with the 3 com-
pression springs to the reverse synchronizer
ring.
226RW120

7B–60MANUAL TRANSMISSION
2. Install the synchronizer outer ring, synchronizer
cone ring, and synchronizer pull ring to the
reverse block ring.
226RW121
3. Turn to 30 degree the reverse synchronizer pull
ring.
226RW080
4. Install the hub sleeve No.3 and reverse block ring
set to the counter 5th gear.
NOTE: Check the hub sleeve No.3 direction, as shown.
Reference: While pushing the 3 inserts,
install the synchronizer ring assembly to the
hub sleeve No.3.
226RW184
5. Slide the hub sleeve No.3.
226RW123

MANUAL TRANSMISSION7B–61
6. Install the counter 5th gear bearing, counter 5th
gear and reverse block ring set to the counter
gear shaft, through the 5th reverse shift arm to the
5th reverse shift rod.
220RW101
7. Using installer 5–8840–2552–0 (J–42796) and a
press, install counter 5th gear spline piece.
NOTE:
Align the projection of the cone ring to the holes of the
5th gear spline piece.
Check that the gear rotates smoothly.
226RW193
8. Using thickness gauge, measure the counter 5th
gear thrust clearance.
Standard: 0.10 – 0.35mm (0.004 – 0.014 in)
220RW100
9. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A2.80 – 2.85 (0.110 – 0.112 in)
B2.85 – 2.90 (0.112 – 0.114 in)
C2.90 – 2.95 (0.114 – 0.116 in)
D2.95 – 3.00 (0.116 – 0.118 in)
E3.00 – 3.05 (0.118 – 0.120 in)
F3.05 – 3.10 (0.120 – 0.122 in)
G3.10 – 3.15 (0.122 – 0.124 in)
226RW027

7B–62MANUAL TRANSMISSION
10. Install the new snap ring.
226RW026
32. Install the shift arm bolts.
1. Install and torque the 2 shift arm bolts.
Torque: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
226RW023
33. Install the shift arm slotted pin.
1. Using a pin punch and a hammer, drive in the
slotted pin to the shift arm.
226RW025
34. Install the transmission case.
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown.
NOTE:
Don’t dry the liquid gasket.
220RW024