OPEL FRONTERA 1998 Workshop Manual

MANUAL TRANSMISSION7B–23
3. Using the M8 1.25 bolt, remove the gear control
rod and the shift lever hausing.
NOTE: Turn the M8 bolt a few times, before remove the
gear control rod.
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4. Remove the 10 bolts and clamp.
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5. Using a plastic hammer, tap the transfer adapter.
NOTE:
Be careful not to lose the pin.
Cover the mainshaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
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7. Disassemble the transfer adapter assembly.
1. Using a torx socket wrench(T40), remove the
plug.
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7B–24MANUAL TRANSMISSION
2. Using a pin punch and hammer, drive out the
slotted spring pin. Remove the reverse restrict
pin.
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3. Remove the oil receiver pipe.
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4. Remove the oil seal.
5. Using socket hexagon wrench, remove the plug.
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8. Remove the front cover.
1. Remove the 8 bolts.
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MANUAL TRANSMISSION7B–25
2. Using a plastic hammer, carefully tap the front
cover.
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9. Remove the front cover oil seal.
1. Mount the front cover through the aluminum plate
in a vise.
2. Using screwdriver, remove oil seal (1).
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10. Remove the transmission case.
1. Using a snap ring expander, remove the 2 snap
rings (1)(2).
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2. Using a plastic hammer, carefully tap the
transmission case.
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7B–26MANUAL TRANSMISSION
11. Mount the intermediate plate.
1. Mount the intermediate plate through the
aluminum plate in a vise.
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12. Remove the slotted spring pin.
1. Using a pin punch and hammer, drive out the pin
from the arm.
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13. Remove the shift arm set bolt.
1. Remove the 2 bolts from the shift arm.
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14. Remove the counter 5th gear.
1. Using 2 screwdrivers and hammer, tap out the
snap ring.
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MANUAL TRANSMISSION7B–27
2. Using remover 5–8840–2550–0 (J–42794) and
attachment 5–8840–2560–0 (J–42988), remove
the 5th gear spline piece.
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3. Remove the hub sleeve No.3, block ring set,
counter 5th gear, bearing and 5th shift arm.
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4. Remove the synchronizer pull ring, synchronizer
cone ring, and synchronizer outer ring from hub
sleeve No.3.
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5. Remove the reverse block ring from the hub
sleeve No.3. Remove the 3 inserts and 3
compression springs.
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7B–28MANUAL TRANSMISSION
15. Remove the thrust washer.
1. Remove the thrust washer from counter gear
shaft.
2. Remove the thrust washer pin from counter gear
shaft.
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16. Remove the bearing plate.
1. Remove the 4 bolts and bearing retainer.
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17. Remove the reverse idle gear.
1. Pull out the shaft foward the rear and remove the
reverse idle gear.
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18. Remove the counter gear shaft.
1. Using snap ring plier, remove counter gear shaft
center bearing snap ring.
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MANUAL TRANSMISSION7B–29
2. Using remover 5–8840–2551–0 (J–42795) and
attachment 5–8840–2560–0 (J–42988), remove
counter gear shaft center bearing.
NOTE: Be careful not to drop the counter gear, when
removing the bearing.
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3. Remove the counter gear from intermediate
plate.
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19. Disassemble the counter gear shaft assembly.
1. Using snap ring pliers, remove the counter gear
shaft front bearing snap ring.
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2. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the bearing.
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7B–30MANUAL TRANSMISSION
20. Remove the top gear shaft.
1. Remove the top gear shaft from mainshaft.
NOTE: Don’t fall needle roller bearing.
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2. Remove the 4th block ring and roller bearing.
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21. Disassemble the top gear shaft assembly.
1. Check for wear or damage.
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2. Remove the front bearing shaft snap ring.
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MANUAL TRANSMISSION7B–31
3. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the bearing.
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22. Remove the mainshaft.
1. Remove mainshaft bearing snap ring.
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2. Using a plastic hammer, tap the 5th-reverse shift
rod at the reverse shift side.
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3. Remove the intermediate plate from a vise.
4. Remove the mainshaft, 1st-2nd shift arm and
3rd-4th shift arm.
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7B–32MANUAL TRANSMISSION
23. Disassemble the mainshaft assembly.
1. Inspect each gear thrust clearance.
1. Using thickness gauge, inspect thrust
clearance (1st gear, 3rd gear).
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2. Mount the mainshaft through the aluminum
plate in a vise.
3. Using a dial indicator, measure each gear
thrust clearance.
Gear
Standard Clearanse
1st0.15 – 0.45 mm (0.0059 – 0.0177 in)
2nd0.10 – 0.25 mm (0.0039 – 0.0098 in)
3rd0.10 – 0.25 mm (0.0039 – 0.0098 in)
226RW070
2. Inspect each gear radial clearance
1. Using a dial indicator, measure the radial
clearance of each gear.
Gear
Standard Clearanse
1st0.020 – 0.074 mm (0.00078 – 0.00291 in)
2nd0.015 – 0.068 mm (0.00059 – 0.00268 in)
3rd0.015 – 0.068 mm (0.00059 – 0.00268 in)
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3. Using 2 screwdrivers and hammer, tap out the
snap ring.
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