manual transmission OPEL FRONTERA 1998 Manual Online

7B–28MANUAL TRANSMISSION
15. Remove the thrust washer.
1. Remove the thrust washer from counter gear
shaft.
2. Remove the thrust washer pin from counter gear
shaft.
226RW018
16. Remove the bearing plate.
1. Remove the 4 bolts and bearing retainer.
226RW016
17. Remove the reverse idle gear.
1. Pull out the shaft foward the rear and remove the
reverse idle gear.
226RW020
18. Remove the counter gear shaft.
1. Using snap ring plier, remove counter gear shaft
center bearing snap ring.
226RW015

MANUAL TRANSMISSION7B–29
2. Using remover 5–8840–2551–0 (J–42795) and
attachment 5–8840–2560–0 (J–42988), remove
counter gear shaft center bearing.
NOTE: Be careful not to drop the counter gear, when
removing the bearing.
226RW199
3. Remove the counter gear from intermediate
plate.
226RW030
19. Disassemble the counter gear shaft assembly.
1. Using snap ring pliers, remove the counter gear
shaft front bearing snap ring.
226RW065
2. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the bearing.
226RW200

7B–30MANUAL TRANSMISSION
20. Remove the top gear shaft.
1. Remove the top gear shaft from mainshaft.
NOTE: Don’t fall needle roller bearing.
226RW029
2. Remove the 4th block ring and roller bearing.
226RW031
21. Disassemble the top gear shaft assembly.
1. Check for wear or damage.
226RW033
2. Remove the front bearing shaft snap ring.
226RW062

MANUAL TRANSMISSION7B–31
3. Using bearing separator 5–8840–0015–0
(J–22912–01) and a press, remove the bearing.
226RW202
22. Remove the mainshaft.
1. Remove mainshaft bearing snap ring.
226RW035
2. Using a plastic hammer, tap the 5th-reverse shift
rod at the reverse shift side.
226RW034
3. Remove the intermediate plate from a vise.
4. Remove the mainshaft, 1st-2nd shift arm and
3rd-4th shift arm.
226RW014

7B–32MANUAL TRANSMISSION
23. Disassemble the mainshaft assembly.
1. Inspect each gear thrust clearance.
1. Using thickness gauge, inspect thrust
clearance (1st gear, 3rd gear).
226RW077
2. Mount the mainshaft through the aluminum
plate in a vise.
3. Using a dial indicator, measure each gear
thrust clearance.
Gear
Standard Clearanse
1st0.15 – 0.45 mm (0.0059 – 0.0177 in)
2nd0.10 – 0.25 mm (0.0039 – 0.0098 in)
3rd0.10 – 0.25 mm (0.0039 – 0.0098 in)
226RW070
2. Inspect each gear radial clearance
1. Using a dial indicator, measure the radial
clearance of each gear.
Gear
Standard Clearanse
1st0.020 – 0.074 mm (0.00078 – 0.00291 in)
2nd0.015 – 0.068 mm (0.00059 – 0.00268 in)
3rd0.015 – 0.068 mm (0.00059 – 0.00268 in)
226RW071
3. Using 2 screwdrivers and hammer, tap out the
snap ring.
226RW053

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.
226RW075
10. Remove the snap ring.
NOTE: Don’t damage the bearing surface.
226RW076
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).
226RW091
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.
226RW052
3. Using a torx socket wrench(T40), remove the 4
plugs.
226RW050
4. Using a magnetic finger, remove 3 springs and
balls.
226RW049
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.
226RW045
9. Using a magnetic finger, remove the interlock pin.
226RW042

MANUAL TRANSMISSION7B–37
10. Using 2 screwdrivers and a hammer, remove 2
snap rings.
226RW041
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