torque OPEL FRONTERA 1998 Workshop Manual

MANUAL TRANSMISSION7B–59
28. Install the reverse idle gear.
1. Install the reverse idle gear and reverse idle gear
shaft.
NOTE:
Insert the reverse idle gear shaft with the slot toward
rear.
Install the reverse idle gear with the reverse shift arm
No.2.
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29. Install the bearing plate.
1. Align the bearing plate to groove of the reverse
idle gear shaft.
Torque: 13 Nꞏm (1.3 kgꞏm/113 lb in)
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30. Install the 5th gear thrust washer.
1. Install the 5th gear thrust washer pin to the
counter gear shaft.
2. Install the 5th gear thrust washer to the counter
gear shaft.
NOTE: Thrust washer must be assembled with the
chamfered face of the washer toward the front.
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31. Install the counter 5th gear.
1. Install the 3 inserts and 3 compression springs to
the reverse block ring.
Reference: Push the 3 inserts with the 3 com-
pression springs to the reverse synchronizer
ring.
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7B–62MANUAL TRANSMISSION
10. Install the new snap ring.
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32. Install the shift arm bolts.
1. Install and torque the 2 shift arm bolts.
Torque: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
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33. Install the shift arm slotted pin.
1. Using a pin punch and a hammer, drive in the
slotted pin to the shift arm.
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34. Install the transmission case.
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown.
NOTE:
Don’t dry the liquid gasket.
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MANUAL TRANSMISSION7B–63
3. Stand the transmission by the wood blocks.
4. Using a plastic hammer, tap the transmission
case and attach it to the intermediate plate.
NOTE: Be careful not to add over force to bearing.
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5. Using a snap ring expander, install the front
bearing shaft snap ring (1) and counter gear shaft
bearing snap ring (2).
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6. Turn over the transmission.
35. Install the front cover.
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown.NOTE:
Don’t dry the liquid gasket.
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3. Clean up and dry the bolts.
4. Apply thread sealant (THREE BOND 1344 or
equivalent) to the 8 bolts.
5. Using 8 bolts, install the front cover to the
transmission case.
Torque: 17 Nꞏm (1.7 kgꞏm/12 lb ft)
NOTE:
Tighten the all bolts evenly.
Be careful not to damage the oil seal.
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7B–64MANUAL TRANSMISSION
6. Check that the top gear shaft and mainshaft
rotate.
36. Install the transfer adapter.
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown.
NOTE:
Don’t dry the liquid gasket.
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3. Using a plastic hammer, tap the transfer adapter
and attach it to the intermediate plate.
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4. Using 10 bolts, install the transfer adapter.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
NOTE:
Tighten the all bolts evenly.
Don’t damage the lip of the oil seal.
Install the wire clamp (9) to the transfer adapter.
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37. Install the gear control box.
1. Align the projection of the shift lever housing to
the shaft rod groove, and install the gear control
rod.
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MANUAL TRANSMISSION7B–65
2. Using a pin punch and hammer, drive in the
slotted spring pin (2) to the shift lever housing.
NOTE: Be carefull not to drop the slotted spring pin.
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3. Apply sealant (THREE BOND 1344 or
equivalent) to the plug (1) thread.
4. Using hexagon wrench, install and torque the
plug (1).
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
220RW010
5. Clean up the bolts and bolt hole.
6. Using 6 bolts, install the gear control box through
the gasket.
Torque 18 Nꞏm (1.8 kgꞏm/13 lb ft)
(6VE1)
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(4JX1)
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7B–66MANUAL TRANSMISSION
38. Install clutch housing.
1. Install the clutch housing to the transmission
case.
Torque: 36 Nꞏm (3.7 kgꞏm/27 lb ft)
NOTE: Tighten the all bolts evenly.
241RW001
39. Install the switches.
1. Install the new gasket to the 1st and 2nd switch.
2. Install the 1st and 2nd switch assembly (8).
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
3. Install the new gasket to the backup light switch.
4. Install the backup light switch assembly (6).
Torque: 44 Nꞏm (4.5 kgꞏm/33 lb ft)
5. Install the new gasket to the neutral switch.
6. Install the neutral switch (7) to the transfer
adapter (4JX1).
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
(4JX1)
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40. Install the clutch release bearing (3) and clutch shift
fork (5).
1. Apply the clutch release grease.
1. Fitting surface of the cylinder push rod.
2. Fitting surface of the release bearing hub.
3. The hole of the fork split pin (4).
2. Apply the clutch release grease.
1. The spline surface of the top gear shaft.
3. Install the clutch shift fork (5).
4. Install the snap pin.
5. Install the clutch release bearing (3) to the clutch
shift fork (5).
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MANUAL TRANSMISSION7B–67
41. Install the drain plug and filler plug.
1. Install the drain plug (1) through the new gasket.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
2. Install the filler plug (2) through the new gasket.
Reference: Plug after the gear oil fill in.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
(6VE1)
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MANUAL TRANSMISSION7B–69
Torque Specifications
E07RW049

7B–70MANUAL TRANSMISSION
Torque Specifications (Cont’d)
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MANUAL TRANSMISSION7B–71
Torque Specifications (Cont’d)
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