manual transmission OPEL FRONTERA 1998 Repair Manual

7B–8MANUAL TRANSMISSION
15. Remove four fuel pipe bracket from the transmission
case (6VE1).
141RW024

MANUAL TRANSMISSION7B–9
16. Remove the slave cylinder heat protector.
17. Remove the harness heat protector (6VE1).
(6VE1)
225RW006
18. Remove two transmission harness clamps and
bracket (6VE1).
19. Remove the slave cylinder.
206RW002
20. Remove the two dust cover from transmission case.
21. Support the transfer case with a jack.22. Remove two engine rear mount nuts.
(6VE1)
022RT002
23. Remove third crossmember (6VE1).
24. Remove third crossmember with rear mount rubber
(4JX1).
(4JX1)
022RW013
25. Remove two engine rear mount bolts (6VE1).
26. Remove the rear mount from the transmission
(6VE1).
27. Remove three flywheel under cover (6VE1).

7B–10MANUAL TRANSMISSION
28. Support the transmission with a transmission jack
and then remove jack from the transfer case side.
220RS001
29. Use the clutch release bearing remover
5–8840–2291–0 (J–39207) to disconnect the clutch
release bearing from the clutch pressure plate.
220RW109
Release bearing disconnection
1. Pull the shift fork toward the transmission to press
the clutch release bearing against the clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.3. Turn the remover to separate the release bearing.
NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.
220RW063
220RW064

MANUAL TRANSMISSION7B–11
220RW119
Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
30. Remove the transmission retaining nuts and bolts.
31. Remove the transmission assembly with transfer
case from the vehicle.
NOTE: Remove the transfer case from the transmission
assembly if the transmission disassembly required.
Refer to Transfer Case in Drive Line/Axle section.
Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front of
transmission is aligned with the rear of the engine.
The slope of the engine and the transmission must be
the same.
3. Align the top gear shaft spline with the clutch driven
plate spline.
220RS005
4. Install the transmission to the engine.
Tighten the transmission retaining nuts and bolts.

7B–12MANUAL TRANSMISSION
(6VE1)
225RW019

MANUAL TRANSMISSION7B–13
(4JX1)
225RW020
5. Apply a force of about 113N (26 Ib) to the tip of the
shift fork in the direction of the transmission to engage
the clutch pressure plate and release bearing.
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage each
other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine while applying a
force of about 25 N (5.5 lb). If the shift fork will not move,
then they are securely engaged.
220RS006
6. Install three flywheel under cover (6VE1).

7B–14MANUAL TRANSMISSION
7. Install the engine rear mount to the transmission case
and tighten the fixing bolts specified torque (6VE1).
Torque: 41 Nꞏm (4.2kgꞏm/30 Ib ft)
8. Install the third crossmember to the frame and tighten
the fixing bolts specified torque.
Torque: 50 Nꞏm (5.1kgꞏm/37 Ib ft)
9. Tighten the engine rear mount nuts specified torque.
Torque: 50 Nꞏm (5.1kgꞏm/37 Ib ft)
10. Remove the transmission jack.
11. Apply the grease to top hole portion of the shift fork.
12. Install the slave cylinder and tighten the fixing bolts
specified torque.
Torque: 43 Nꞏm (4.4kgꞏm/32 Ib ft)
13. Install the clutch dust cover to the clutch housing and
tighten the fixing bolts specified torque.
Torque: 8 Nꞏm (0.8kgꞏm/69 Ib in)
220RS007
14. Install the slave cylinder heat protector to the slave
cylinder.
15. Install bracket and two transmission harness clamps
to the transmission case (6VE1).
16. Install harness heat protector (6VE1).(6VE1)
225RW006
17. Install four fuel pipe bracket (6VE1).

MANUAL TRANSMISSION7B–15
141RW024
18. Connect the speedometer sensor and 2WD–4WD
actuator harness connector.
826RW024

7B–16MANUAL TRANSMISSION
19. Connect the backup lamp switch, 4WD indicator
switch, and 1-2 indicator switch harness connectors.
826RW023
20. Install the front and 3 way exhaust pipe (6VE1).
Install the exhaust pipe with catalytic converter
(4JX1).
Torque:
Exhaust pipe to exhaust manifold:
67 Nꞏm (6.8 kgꞏm/49 Ib ft)
Exhaust pipe flange bolt:
43 Nꞏm (4.4 kgꞏm/32 Ib ft)
(4JX1)
150RW041
21. Connect two oxygen sensor connectors to the
transmission harness (6VE1).
22. Install the front propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 Ib ft)
23. Install the rear propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 Ib ft)24. Install transfer protector and tighten the fixing bolts
specified torque.
Torque: 37 Nꞏm (3.8 kgꞏm/27 Ib ft)
25. Install the transmission control lever and transfer
control lever.
235RW014
26. Install the grommet assembly.
27. Install the front console assembly.
28. Install the gear control lever knob.
29. Connect battery ground cable.
30. Install engine hood.

MANUAL TRANSMISSION7B–17
Rear Oil Seal (Transfer Adapter)
Removal
1. Remove the transfer case assembly from the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
2. Remove the rear oil seal from the transfer adapter.
220RW090
Installation
1. Use 5–8840–2558–0 (J–42802) transfer adapter oil
seal installer, and install the rear oil seal to the transfer
adapter.
2. Apply grease to the oil seal lip.
3. Install the transfer case assembly to the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
220RW115