2.2 OPEL FRONTERA 1998 Owner's Guide

7A–50
AUTOMATIC TRANSMISSION (4L30–E)
22. Second clutch end play measurement
1. Install the 5–8840–2262–0 (J–23085–A)
Selective washer gauging tool (with spacer ring)
on the case flange and against the intermediate
shaft.
2. Position the inner shaft of the gauging tool against
the thrust surface of the second clutch hub.
3. Tighten thumb screw. Remove the tool.
4. Fit the spacer ring on the inner shaft of the tool.
5. Measure the gap, and select the appropriate
washer as shown in the chart.
Selective Thrust Washer
Gap: mm(in)Color
1.53 – 1.63 (0.060 – 0.064)Yellow
1.72 – 1.82 (0.068 – 0.072)Red
1.91 – 2.01 (0.075 – 0.079)Black
2.10 – 2.20 (0.083 – 0.087)Natural
2.29 – 2.39 (0.090 – 0.094)Green
2.48 – 2.58 (0.098 – 0.102)Blue
FOLLOWING THE PROCEDURE SHOULD RE-
SULT IN FINAL END–PLAY FROM 0.36 mm TO
0.79 mm (0.014 in TO 0.031 in)
247RW003
247RW004
23. Inspect fourth clutch piston seals and replace if
necessary.
Lubricate 5–8840–2267–0 (J–38554) fourth clutch
piston fitter and install it on fourth clutch piston (19).
Install fourth clutch piston (19) in adapter case (20).
Remove fitter.
252RW006
24. Install retainer and spring assembly (22) into fourth
clutch piston (21).

7A–52
AUTOMATIC TRANSMISSION (4L30–E)
33. Install fourth clutch retainer (31) with the notch facing
up and positioned towards valve body surface.
252RW004
34. Overdrive clutch end play measurement
1. Install the 5–8840–2262–0 (J–23085–A)
selective washer gauging tool on the adapter
case flange and against the input shaft.
2. Position the inner shaft of the tool against the
thrust surface of the overrun clutch housing.
3. Tighten thumb screw. Remove the tool.
4. Measure gap. Select appropriate size washer as
shown in the chart.
5. Set selective thrust washer aside.
Selective Thrust Washer
Gap: mm(in)Color
1.53 – 1.63 (0.060 – 0.064)Yellow
1.72 – 1.82 (0.068 – 0.072)Red
1.91 – 2.01 (0.075 – 0.079)Black
2.10 – 2.20 (0.083 – 0.087)Natural
2.29 – 2.39 (0.090 – 0.094)Green
2.48 – 2.58 (0.098 – 0.102)Blue
FOLLOWING THE PROCEDURE SHOULD RE-
SULT IN FINAL END–PLAY FROM 0.1 mm TO 0.8
mm (0.004 in TO 0.03 in)
252RW008
252RW009
35. Install selective washer (32).
NOTE: Use petroleum jelly to hold selective washer in
place.
36. Install gasket (33).
37. Install converter housing and oil pump assembly (34)
to adapter case.
Fit and tighten seven outer 13 mm screws.
To r q u e : 3 9 N
m (4.0 kgꞏm/29 lb ft)

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–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

Wiring – Wire Size
The size of wire used in a circuit is determined by the
amount of current (amperage), the length of the circuit,
and the voltage drop allowed. The following wire size and
load capacity, shown below, are specified by AWG
(American Wire Gauge). (Nominal size means
approximate cross sectional area (1).)
Wiring – Wire Size Table
Nominal sizeCross sectional Outside diameter Allowable
area (mm2) (mm) current (A)
0.3 0.372 1.5 9
0.5 0.563 1.7 12
0.85 0.885 1.9 16
1.25 1.287 2.2 21
22.0912.728
3 3.296 3.6 37.5
55.2274.453
87.9525.567
15 13.36 7.0 75
20 20.61 8.2 97
1

874RS006
874RY00005
874RY00006
SENSOR TO BE LOCATED
AT 7TH LINE FROM LEFT
57.5mm(2.26 in.) 21
Lower case Upper case
874RX021

12
3
4
874RX022
SENSOR TO BE LOCATED
AT 7TH LINE FROM LEFT
57.5mm(2.26 in.) 21
Lower case Upper case
874RX021

Temperature on the Sensor
Temperature Detector(¡C)
Sensor Resistance
Value(k‰)
20



25


30AU
T
O
4321
-20 0 5 10 15 20
25 30
-10 0 10 20 30 40
17.09
9.93
3.75
2.24
6.0
1.6 30.69
865RX007
‰
0
10 0 -10 -20 30 4020 5 10 15 20 25 30
Temperature on the Sensor
Temperature Detector(¡C)
Sensor Resistance
Value(k‰)
17.09 30.69
9.93
6.0
3.75
2.24
1.6
C01RX012
— Testing rod12
A
Current
value
40 A or more
+
12
21
D06RY00001

4A1–15 DIFFERENTIAL (FRONT)
8. Select the shim using the chart;
Pinion marking+10+8+6+4+20–2–4–6–8–10
Dial indicator
reading
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)
0.0812.18
(0.0858)
0.0822.18
(0.0858)2.20
(0.0866)
0.0832.18
(0.0858)2.20
(0.0866)2.23
(0.0882)
0.0842.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)
0.0852.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)
0.0862.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)
0.0872.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)
0.0882.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)
0.0892.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)
0.0902.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)
0.0912.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)
0.0922.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)
0.0932.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)
0.0942.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)
0.0952.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)
0.0962.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0972.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0982.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0992.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
02.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0012.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0022.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0032.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0042.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0052.54
(0.1000)2.56
(0.1008)
0.0062.56
(0.1008)
NOTE: When ordering shims, find the part number in the
parts catalog by using the thickness of shims listed in the
above table.4. Place the shim on the drive pinion, with the chamfered
side turned towards the pinion head then install the
inner bearing onto the pinion using an installer
9–8522–1165–0 and a press.

4A2A–18
DIFFERENTIAL (REAR 220mm)
8. Select the shim using the chart;
Pinion
marking
Dial
indicator
reading
(Inches)+10+8+6+4+20–2–4–6–8–10
0.0731.94
(0.0764)1.96
(0.0772)
0.0741.94
(0.0764)1.96
(0.0772)1.98
(0.0779)
0.0751.94
(0.0764)1.96
(0.0772)1.98
(0.0779)2.00
(0.0787)
0.0761.94
(0.0764)1.96
(0.0772)1.98
(0.0779)2.00
(0.0787)2.02
(0.0795)2.04
(0.0803)
0.0771.96
(0.0772)1.98
(0.0779)2.00
(0.0787)2.02
(0.0795)2.04
(0.0803)2.06
(0.0811)
0.0781.94
(0.0764)1.96
(0.0772)1.98
(0.0779)2.00
(0.0787)2.02
(0.0795)2.04
(0.0803)2.06
(0.0811)2.08
(0.0819)
0.0791.94
(0.0764)1.96
(0.0772)1.98
(0.0779)2.00
(0.0787)2.02
(0.0795)2.04
(0.0803)2.06
(0.0811)2.08
(0.0819)2.10
(0.0827)
0.0801.94
(0.0764)1.96
(0.0772)1.98
(0.0779)2.00
(0.0787)2.02
(0.0795)2.04
(0.0803)2.06
(0.0811)2.08
(0.0819)2.10
(0.0827)2.12
(0.0835)2.14
(0.0842)
0.0811.96
(0.0772)1.98
(0.0779)2.00
(0.0787)2.02
(0.0795)2.04
(0.0803)2.06
(0.0811)2.08
(0.0819)2.10
(0.0827)2.12
(0.0835)2.14
(0.0842)2.16
(0.0850)
0.0821.98
(0.0779)2.00
(0.0787)2.02
(0.0795)2.04
(0.0803)2.06
(0.0811)2.08
(0.0819)2.10
(0.0827)2.12
(0.0835)2.14
(0.0842)2.16
(0.0850)2.18
(0.0858)
0.0832.00
(0.0787)2.02
(0.0795)2.04
(0.0803)2.06
(0.0811)2.08
(0.0819)2.10
(0.0827)2.12
(0.0835)2.14
(0.0842)2.16
(0.0850)2.18
(0.0858)2.20
(0.0866)
0.0842.04
(0.0803)2.06
(0.0811)2.08
(0.0819)2.10
(0.0827)2.12
(0.0835)2.14
(0.0842)2.16
(0.0850)2.18
(0.0858)2.20
(0.0866)2.22
(0.0874)2.24
(0.0882)
0.0852.06
(0.0811)2.08
(0.0819)2.10
(0.0827)2.12
(0.0835)2.14
(0.0842)2.16
(0.0850)2.18
(0.0858)2.20
(0.0866)2.22
(0.0874)2.24
(0.0882)2.26
(0.0890)
0.0862.08
(0.0819)2.10
(0.0827)2.12
(0.0835)2.14
(0.0842)2.16
(0.0850)2.18
(0.0858)2.20
(0.0866)2.22
(0.0874)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)
0.0872.12
(0.0835)2.14
(0.0842)2.16
(0.0850)2.18
(0.0858)2.20
(0.0866)2.22
(0.0874)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.30
(0.0906)2.32
(0.0913)
0.0882.14
(0.0842)2.16
(0.0850)2.18
(0.0858)2.20
(0.0866)2.22
(0.0874)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.30
(0.0906)2.32
(0.0913)2.34
(0.0921)
0.0892.16
(0.0850)2.18
(0.0858)2.20
(0.0866)2.22
(0.0874)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.30
(0.0906)2.32
(0.0913)2.34
(0.0921)2.36
(0.0929)
0.0902.18
(0.0858)2.20
(0.0866)2.22
(0.0874)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.30
(0.0906)2.32
(0.0913)2.34
(0.0921)2.36
(0.0929)
0.0912.22
(0.0874)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.30
(0.0906)2.32
(0.0913)2.34
(0.0921)2.36
(0.0929)
0.0922.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.30
(0.0906)2.32
(0.0913)2.34
(0.0921)2.36
(0.0929)
0.0932.26
(0.0890)2.28
(0.0898)2.30
(0.0906)2.32
(0.0913)2.34
(0.0921)2.36
(0.0929)
0.0942.28
(0.0898)2.30
(0.0906)2.32
(0.0913)2.34
(0.0921)2.36
(0.0929)
0.0952.32
(0.0913)2.34
(0.0921)2.36
(0.0929)
0.0962.34
(0.0921)2.36
(0.0929)
0.0972.36
(0.0929)
NOTE: When ordering shims, find the part number in the
parts catalog by using the thickness of shims listed in the
above table.