OPEL FRONTERA 1998 Workshop Manual

MANUAL TRANSMISSION7B–33
4. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the following
parts.
1. 5th gear (1).
2. Mainshaft bearing (2).
3. 1st gear thrust washer (3).
4. 1st gear (4).
226RW197
5. Remove following parts from mainshaft.
1. Synchronizer assembly (1).
2. 1st gear thrust washer pin (3).
3. 1st gear needle roller bearing (4).
4. 1st gear bearing spacer (2).
226RW146
6. Using 2 screwdrivers and hammer, tap out snap
ring.
226RW073
7. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the following
parts.
1. Clutch hub No.1 assembly (1).
2. Synchronizer assembly (2).
3. 2nd gear (3).
4. 2nd gear needle roller bearing (4).
226RW198

7B–34MANUAL TRANSMISSION
8. Remove the reverse gear from clutch hub No.1.
9. Remove the 3 inserts and 3 compression springs.
When removing the inserts, push the insert
spring with a screwdriver.
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10. Remove the snap ring.
NOTE: Don’t damage the bearing surface.
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11. Using a press, remove following parts.
1. Clutch hub No.2 assembly (1).
2. 3rd block ring (2).
3. 3rd gear (3).
4. 3rd gear needle roller bearing (4).
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12. Using screwdriver, remove the 2 insert springs,
hub sleeve No.2, clutch hub No.2 and 3 inserts.
226RW090

MANUAL TRANSMISSION7B–35
24. Remove the shift parts and interlock parts.
1. Mount the intermediate plate through the
aluminum plate in a vise.
2. Using a plastic hammer, tap the 5th shift rod on
the neutral.
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3. Using a torx socket wrench(T40), remove the 4
plugs.
226RW050
4. Using a magnetic finger, remove 3 springs and
balls.
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5. Using 2 screwdrivers and a hammer, remove 2
snap rings from each shift fork rod.
226RW048

7B–36MANUAL TRANSMISSION
6. Pull out the 3rd–4th shift rod at the rear.
226RW047
7. Using a magnetic finger, remove the interlock pin
and straight pin.
226RW043
8. Pull out the 1st–2nd shift rod at the rear.
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9. Using a magnetic finger, remove the interlock pin.
226RW042

MANUAL TRANSMISSION7B–37
10. Using 2 screwdrivers and a hammer, remove 2
snap rings.
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11. Pull out the 5th-reverse shift rod at the front.
226RW040
12. Using a magnetic finger, remove the interlock pin
from the intermediate plate. Remove the ball
from the reverse shift arm No.1.
226RW039
13. Pull out at the rear reverse shift rod, reverse shift
arm No.1 and reverse shift arm No.2 at the same
time.
226RW038

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.
226RW056
16. Remove the reverse shift arm No.2 E–ring.
Remove the reverse shift arm No.2 from reverse
shift arm No.1.
226RW089
17. Remove the 2 bolts and reverse shift arm bracket.
226RW054

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)
226RW085
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)
226RW083
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.
226RW196
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.
226RW062
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)
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