OPEL FRONTERA 1998 Workshop Manual

MANUAL TRANSMISSION7B–13
(4JX1)
225RW020
5. Apply a force of about 113N (26 Ib) to the tip of the
shift fork in the direction of the transmission to engage
the clutch pressure plate and release bearing.
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage each
other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine while applying a
force of about 25 N (5.5 lb). If the shift fork will not move,
then they are securely engaged.
220RS006
6. Install three flywheel under cover (6VE1).

7B–14MANUAL TRANSMISSION
7. Install the engine rear mount to the transmission case
and tighten the fixing bolts specified torque (6VE1).
Torque: 41 Nꞏm (4.2kgꞏm/30 Ib ft)
8. Install the third crossmember to the frame and tighten
the fixing bolts specified torque.
Torque: 50 Nꞏm (5.1kgꞏm/37 Ib ft)
9. Tighten the engine rear mount nuts specified torque.
Torque: 50 Nꞏm (5.1kgꞏm/37 Ib ft)
10. Remove the transmission jack.
11. Apply the grease to top hole portion of the shift fork.
12. Install the slave cylinder and tighten the fixing bolts
specified torque.
Torque: 43 Nꞏm (4.4kgꞏm/32 Ib ft)
13. Install the clutch dust cover to the clutch housing and
tighten the fixing bolts specified torque.
Torque: 8 Nꞏm (0.8kgꞏm/69 Ib in)
220RS007
14. Install the slave cylinder heat protector to the slave
cylinder.
15. Install bracket and two transmission harness clamps
to the transmission case (6VE1).
16. Install harness heat protector (6VE1).(6VE1)
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17. Install four fuel pipe bracket (6VE1).

MANUAL TRANSMISSION7B–15
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18. Connect the speedometer sensor and 2WD–4WD
actuator harness connector.
826RW024

7B–16MANUAL TRANSMISSION
19. Connect the backup lamp switch, 4WD indicator
switch, and 1-2 indicator switch harness connectors.
826RW023
20. Install the front and 3 way exhaust pipe (6VE1).
Install the exhaust pipe with catalytic converter
(4JX1).
Torque:
Exhaust pipe to exhaust manifold:
67 Nꞏm (6.8 kgꞏm/49 Ib ft)
Exhaust pipe flange bolt:
43 Nꞏm (4.4 kgꞏm/32 Ib ft)
(4JX1)
150RW041
21. Connect two oxygen sensor connectors to the
transmission harness (6VE1).
22. Install the front propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 Ib ft)
23. Install the rear propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 Ib ft)24. Install transfer protector and tighten the fixing bolts
specified torque.
Torque: 37 Nꞏm (3.8 kgꞏm/27 Ib ft)
25. Install the transmission control lever and transfer
control lever.
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26. Install the grommet assembly.
27. Install the front console assembly.
28. Install the gear control lever knob.
29. Connect battery ground cable.
30. Install engine hood.

MANUAL TRANSMISSION7B–17
Rear Oil Seal (Transfer Adapter)
Removal
1. Remove the transfer case assembly from the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
2. Remove the rear oil seal from the transfer adapter.
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Installation
1. Use 5–8840–2558–0 (J–42802) transfer adapter oil
seal installer, and install the rear oil seal to the transfer
adapter.
2. Apply grease to the oil seal lip.
3. Install the transfer case assembly to the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
220RW115

7B–18MANUAL TRANSMISSION
Transmission (AR-5)
Disassembled View
226RW182
Legend
(1) Snap Ring
(2) Bearing
(3) Top Gear Shaft
(4) Block Ring
(5) Roller Bearing
(6) Snap Ring
(7) Clutch Hub No.2 Assembly
(8) 3rd Block Ring
(9) 3rd Gear
(10) 3rd Gear Needle Roller Bearing
(11) Mainshaft
(12) Thrust Washer Pin
(13) 2nd Gear Needle Roller Bearing
(14) 2nd Gear
(15) Synchronizer Assembly(16) Clutch Hub No.1 Assembly
(17) Snap Ring
(18) Synchronizer Assembly
(19) 1st Gear
(20) 1st Gear Bearing Spacer
(21) 1st Gear Needle Roller Bearing
(22) 1st Gear Thrust Washer
(23) Mainshaft Bearing
(24) Snap Ring
(25) 5th Gear
(26) Snap Ring
(27) Intermediate Plate
(28) Bearing Retainer
(29) Snap Ring
(30) Front Bearing Assembly
(31) Counter Gear Shaft

MANUAL TRANSMISSION7B–19
(32) Thrust Washer Pin
(33) Reverse Idle Gear
(34) Reverse Idle Gear Shaft
(35) Counter Gear Shaft Center Bearing
(36) Snap Ring
(37) Thrust Washer
(38) Roller Bearing(39) Counter 5th Gear
(40) Reverse Block Ring
(41) Synchronizer Assembly
(42) Hub Sleeve No.3
(43) 5th Gear Spline Piece
(44) Snap Ring
226RW00001
Legend
(1) 3rd-4th Shift Arm
(2) 1st-2nd Shift Arm
(3) 3rd-4th Shift Rod
(4) Ball
(5) Spring
(6) 1st-2nd Shift Rod
(7) Snap Ring
(8) Interlock Pin(9) Reverse Shift Arm Bracket
(10) E–Ring
(11) Reverse Shift Arm No.2
(12) Reverse Shift Arm No.1
(13) 5th Reverse Shift Rod
(14) Spring Pin
(15) 5th Shift Arm
(16) Reverse Shift Rod

7B–20MANUAL TRANSMISSION
220RW095
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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