manual transmission OPEL FRONTERA 1998 Owners Manual

7B–38MANUAL TRANSMISSION
14. Pull out reverse shift rod from reverse shift arm
No.1.
NOTE: Be sure remove at the rear.
226RW055
15. Using a magnetic finger, remove the ball and
spring from reverse shift arm No.1.
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16. Remove the reverse shift arm No.2 E–ring.
Remove the reverse shift arm No.2 from reverse
shift arm No.1.
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17. Remove the 2 bolts and reverse shift arm bracket.
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MANUAL TRANSMISSION7B–39
Inspection
1. Counter 5th gear radial clearance.
1. Install the following parts to the counter gear
shaft.
1. Counter 5th gear thrust washer pin (1).
2. Counter 5th gear thrust washer (2).
3. Counter 5th gear needle bearing( 3).
4. Counter 5th gear (4).
226RW088
2. Mount the counter gear shaft through the
aluminum plate in vise.
3. Using a dial indicator, measure the counter 5th
gear radial clearance.
Standard: 0.015 – 0.068 mm
(0.00059 – 0.00268 in)
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4. Using a inside dial indicator, measure the gear
inside diameter.
Standard: 38.015 – 38.040 mm
(1.49665 – 1.49763 in)
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2. 5th-reverse shift arm and hub sleeve No.3 clearance.
1. Using a vernier caliper, measure the 5th-reverse
shift arm thickness.
Reference: 10.2 mm (0.402 in)
2. Using a vernier caliper, measure the center
groove of hub sleeve No.3. Calculate the
clearance between the hub sleeve No.3 and shift
arm.
Standard: 0.26 – 0.84 mm (0.0102 – 0.0331 in)
Reference: Center groove dimension 10.5mm
(0.413 in)
226RW086

7B–40MANUAL TRANSMISSION
3. Reverse block ring set.
1. Using a thickness gauge, measure the clearance
between the counter 5th gear spline piece and
reverse block ring.
Standard: 0.7 – 1.7 mm (0.028 – 0.067 in)
226RW084
4. Reverse idle gear and reverse idle gear shaft.
1. Mount the reverse idle gear and reverse idle gear
shaft in a vise.
2. Using a dial indicator, measure the reverse idle
gear radial clearance.
Standard: 0.040–0.082mm (0.0016–0.0032in)
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3. If the clearance exceeds the maximum, measure
the gear inside diameter and shaft diameter.
Standard
Shaft Diameter: 23.979 – 24.000 mm
(0.94405 – 0.94488 in)
Gear Diameter: 24.040 – 24.061 mm
(0.94645 – 0.94728 in)
226RW082
5. Reverse shift arm No.2 thrust clearance.
1. Using a thickness gauge, measure the clearance
between the reverse idle gear and shift arm No.2.
Standard: 0.05 – 0.35 mm (0.002 – 0.014 in)
226RW081

MANUAL TRANSMISSION7B–41
Reassembly
1. Install the top gear shaft assembly.
1. Using installer 5–8840–2559–0 (J–42904) and a
press, install a new bearing.
NOTE: Outer race snap ring groove (1) toward front.
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2. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A2.10 – 2.15 mm (0.083 – 0.085 in)
B2.15 – 2.20 mm (0.085 – 0.087 in)
C2.20 – 2.25 mm (0.087 – 0.089 in)
D2.25 – 2.30 mm (0.089 – 0.091 in)
E2.30 – 2.35 mm (0.091 – 0.093 in)
F2.35 – 2.40 mm (0.093 – 0.095 in)
G2.40 – 2.45 mm (0.095 – 0.097 in)
226RW061
3. Using a snap ring expander, install the new snap
ring.
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4. Install the 4th block ring.
226RW063

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)
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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.
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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)
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2. Turn the synchronizer ring in one direction while
pushing it to the gear cone. Check that the ring
locks.
226RW106

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)
226RW093
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)

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

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.
226RW109
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.
226RW205
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)
226RW111