lock OPEL FRONTERA 1998 Workshop Manual

7B–42MANUAL TRANSMISSION
5. Using a thickness gauge, measure the clearance
between the 4th block ring back and gear spline
end.
Standard: 0.75 – 1.65 mm (0.030 – 0.065 in)
226RW064
6. Check the braking effect of the block ring. Turn
the block ring in one direction while pushing it to
the gear cone. Check that the ring locks. If it does
not lock, replace the block ring.
226RW060
7. Install the needle roller bearing.
2. Reassemble the mainshaft assembly.
NOTE: Apply all parts with engine oil before installing
them.3. Inspect block ring
1. Using a thickness gauge, measure the clearance
between the synchronizer ring back and gear
spline end.
Gear
Standard Clearanse
1st0.80–1.60mm (0.032–0.063in)
2nd0.65–1.75mm (0.026–0.069in)
3rd0.75–1.65mm (0.030–0.065in)
226RW105
2. Turn the synchronizer ring in one direction while
pushing it to the gear cone. Check that the ring
locks.
226RW106

7B–44MANUAL TRANSMISSION
226RW096
7. Inspect mainshaft.
1. Using a micrometer, measure the outer diameter
of the mainshaft journal.
Measure
Position
Standard
A37.984 – 38.000 mm (1.4954 – 1.4961 in)
B46.984 – 47.000 mm (1.8498 – 1.8504 in)
C38.979 – 38.995 mm (1.5346 – 1.5352 in)
226RW078
2. Using a micrometer, measure the mainshaft
flange thickness.
Standard: 5.0 mm (0.197 in)
226RW079
3. Install the mainshaft to V-blocks.
4. Use a dial indicator to measure the mainshaft
central portion run-out.
Standard: less than 0.015 mm (0.0006 in)
226RW097

MANUAL TRANSMISSION7B–45
8. Install 3rd gear.
1. Install the 3rd gear needle bearing, 3rd gear and
3rd block ring to the mainshaft.
226RW098
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.
226RW099
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.
226RW206
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)
226RW102

7B–46MANUAL TRANSMISSION
5. Using a snap ring expander, install the new snap
ring.
NOTE: Be careful not to damage the bearing surface.
226RW101
6. Using a thickness gauge, inspect the 3rd gear
thrust clearance.
Standard: 0.10 – 0.25mm (0.004 – 0.010 in)
226RW103
10. Install the 2nd gear.
1. Install the synchronizer ring set No.1 to the 2nd
gear.
NOTE: Align the nail of middle ring with gear spline slots.
226RW104
2. Install the needle roller bearing, 2nd gear and 2nd
gear block ring set to the mainshaft.
226RW107

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.
226RW044
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–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