manual transmission OPEL FRONTERA 1998 Workshop Manual

7B–48MANUAL TRANSMISSION
5. Using a screwdriver and hammer, install the snap
ring.
NOTE: Be careful not to damage the bearing surface.
6. Check that the gear rotates smoothly.
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7. Using a dial indicator, measure the 2nd gear
thrust clearance.
Standard: 0.10 – 0.25mm (0.004 – 0.010 in)
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12. Install the 1st gear.1. Install the following parts:
1. 1st gear bearing spacer (4).
2. 1st gear needle roller bearing (3).
3. Synchronizer assembly (2).
4. 1st gear (1).
NOTE:
Align the projection of inner ring with hub No.1 slots.
Check that the gear rotates smoothly.
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2. Install the 1st gear thrust washer pin and 1st gear
thrust washer to the mainshaft.
NOTE: Align the straight pin with the thrust washer slot.
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MANUAL TRANSMISSION7B–49
13. Install the mainshaft center bearing.
1. Using installer 5–8840–2555–0 (J–42799) and a
press, install the mainshaft center bearing.
NOTE: Center bearing snap ring groove toward rear.
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2. Using a thickness gauge, measure 1st gear thrust
clearance.
Standard: 0.10 – 0.45mm (0.004 – 0.018 in)
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14. Install the 5th gear.
1. Using installer 5–8840–2555–0 (J–42799) and a
press, install the 5th gear.
2. Select a snap ring that will allow minimum axial
play.Mark
Thickness
C2.75 – 2.80 mm (0.108 – 0.110 in)
D2.80–2.85mm (0.110–0.112in)
E2.85–2.90mm (0.112–0.114in)
F2.90–2.95mm (0.114–0.116in)
G2.95–3.00mm (0.116–0.118in)
H3.00 – 3.05 mm (0.118 – 0.120 in)
J3.05–3.10mm (0.120–0.122in)
K3.10–3.15mm (0.122–0.124in)
L3.15–3.20mm (0.124–0.126in)
M3.20–3.25mm (0.126–0.128in)
N3.25–3.30mm (0.128–0.130in)
P3.30–3.35mm (0.130–0.132in)
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3. Using a screwdriver and hammer, install the new
snap ring.
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7B–50MANUAL TRANSMISSION
15. Inspect each gear radial clearance.
1. Mount the mainshaft through the aluminum plate
in a vise.
2. Using a dial indicator, measure the radial
clearance of each gear.
Gear
Standard Clearanse
1st0.020 – 0.073 mm (0.0008 – 0.0029 in)
2nd0.015 – 0.068 mm (0.0006 – 0.0027 in)
3rd0.015 – 0.068 mm (0.0006 – 0.0027 in)
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16. Install the counter gear shaft.
1. Check the new counter front bearing inner race
and the side race, as shown.
2. Using installer 5–8840–2556–0 (J–42800) and a
press, install the counter gear shaft front bearing.
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3. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A2.00–2.05mm (0.079–0.081in)
B2.05–2.10mm (0.081–0.083in)
C2.10–2.15mm (0.083–0.085in)
D2.15–2.20mm (0.085–0.087in)
E2.20–2.25mm (0.087–0.089in)
F2.25–2.30mm (0.089–0.091in)
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4. Using a snap ring expander, install the new snap
ring.
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MANUAL TRANSMISSION7B–51
17. Install the front cover.
1. Using installer 5–8840–2557–0 (J–42801), grip
5–8840–0007–0 (J–8092) and a hammer, drive in
a new oil seal.
Drive in depth (from cover end): 11.7
0.5 mm
(0.46
0.02 in)
2. Apply grease to the seal lip.
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18. Install the transfer adapter.
1. Using installer 5–8840–2558–0 (J –42802), and a
hammer drive in a new oil seal.
Drive in depth (from transfer adapter):
10.95
0.5 mm (0.431 0.02 in)
2. Apply grease to the oil seal lip.
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3. Install the oil receiver pipe.
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4. Install the reverse restrict to the transfer adapter.
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7B–52MANUAL TRANSMISSION
5. Using a pin punch and hammer, drive in the
slotted spring pin.
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6. Clean up the plug and plug hole.
7. Apply sealant to the plug threads. (THREE BOND
1344 or equivalent)
8. Using a torx socket wrench(T40), install and
torque the plug.
Torque: 19 Nꞏm (1.9 kgꞏm/14 lb ft)
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9. Using hexagon wrench, install and torque the
plug.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
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19. Install the reverse shift arm No.1 and reverse shift
arm No.2.
1. Mount the intermediate plate through the
aluminum plate in a vise.
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MANUAL TRANSMISSION7B–53
2. Using 2 bolts, install reverse shift arm bracket.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
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3. Install reverse shift arm No.2 to the reverse shift
arm No.1. Using screwdriver and a hammer,
install the new E-ring.
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4. Install reverse shift arm No.2 to the reverse shift
arm bracket.
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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.
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7B–54MANUAL TRANSMISSION
2. Install the reverse shift rod from the rear side by
pushing the ball on using a screwdriver.
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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.
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3. Put in the reverse-5th shift rod from the front.
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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.
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MANUAL TRANSMISSION7B–55
22. Install 1st–2nd shift rod.
1. Install the interlock pin to the intermediate plate.
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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.
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2. Put in the 3rd–4th shift rod from the rear.
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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.
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2. Install the 3 shift detent ball and springs to the
intermediate plate.
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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)
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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.
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MANUAL TRANSMISSION7B–57
2. Install the shift arm No.1 and No.2 to the
mainshaft.
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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.
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4. Using a snap ring expander, install the snap ring.
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5. Using a plastic hammer, tap the 5th-reverse shift
rod at the neutral shift.
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