OPEL FRONTERA 1998 Workshop Manual

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)
226RW095
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.
226RW108
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

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.
226RW112
7. Using a dial indicator, measure the 2nd gear
thrust clearance.
Standard: 0.10 – 0.25mm (0.004 – 0.010 in)
226RW113
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.
226RW114
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.
226RW115

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.
226RW195
2. Using a thickness gauge, measure 1st gear thrust
clearance.
Standard: 0.10 – 0.45mm (0.004 – 0.018 in)
226RW118
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)
226RW203
3. Using a screwdriver and hammer, install the new
snap ring.
226RW127

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)
226RW071
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.
226RW194
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)
226RW128
4. Using a snap ring expander, install the new snap
ring.
226RW129

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.
220RW113
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.
220RW114
3. Install the oil receiver pipe.
220RW011
4. Install the reverse restrict to the transfer adapter.
226RW059

7B–52MANUAL TRANSMISSION
5. Using a pin punch and hammer, drive in the
slotted spring pin.
226RW058
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)
220RW013
9. Using hexagon wrench, install and torque the
plug.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
220RW014
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.
226RW057