Opel Frontera UE. Manual - part 1049

MANUAL TRANSMISSION

7B–41

Block Ring and Dog Teeth Clearance

Standard

Limit

1.5 mm (0.059 in)

0.8 mm (0.032 in)

1st–2nd Synchronizer (3–CONE)

D

Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.

226RS036

If the measured value exceeds the specified limit,the
1st–2nd synchronizer assembly must be replaced.

Block Ring and Dog Teeth Clearance

Standard

Limit

1.5 mm (0.059 in)

0.8 mm (0.032 in)

Block Ring and Insert Clearance

D

Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.

226RS037

If the measured value exceeds the specified limit, the
block ring and the insert must be replaced.

Block and Insert Clearance

 

Standard

Limit

3rd–4th

3.46 – 3.74 mm

(0.136 – 0.147 in)

4.0 mm

(0.158 in)

1st–2nd

4.34 – 4.66 mm

(0.171 – 0.183 in)

4.9 mm

(0.193 in)

Rev–5th

3.59 – 3.91 mm

(0.141 – 0.154 in)

4.1 mm

(0.161 in)

Clutch Hub and Insert Clearance

D

Use a thickness gauge to measure the clearance
between the clutch hub and the insert.

226RS038

If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.

Clutch Hub and Insert Clearance

 

Standard

Limit

3rd–4th

0.01 – 0.19 mm

(0.0004 – 0.0075 in)

0.3 mm

(0.012 in)

1st–2nd

0.09 – 0.31 mm

0.4 mm

Rev–5th

(0.0035 – 0.0122 in)

(0.016 in)

7B–42

MANUAL TRANSMISSION

Mainshaft Run-out

D

Install the mainshaft to V-blocks.

D

Use a dial indicator to measure the mainshaft central
portion run-out.

226RS039

If the measured mainshaft run-out exceeds the
specified limit, the mainshaft must be replaced.

Mainshaft Run–out

Limit: 0.05 mm (0.0020 in)

Gear Inside Diameter

D

Use an inside dial indicator to measure the gear inside
diameter.

226RS040

If the measured value is less than the specified limit,
the gear must be replace.

Gear Inside Diameter

 

Standard

Limit

1st

45.000 – 45.013 mm

45.100 mm

3rd

(1.771 – 1.772 in)

(1.776 in)

2nd

52.000 – 52.013 mm

(2.047 – 2.048 in)

52.100 mm

(2.051 in)

Rev.

48.000 – 48.013 mm

(1.889 – 1.890 in)

48.100 mm

(1.894 in)

5th

32.000 – 32.013 mm

(1.259 – 1.260 in)

32.100 mm

(1.246 in)

Reverse Idler Gear and Idler Gear Shaft
Clearance

D

Use a micrometer to measure the idler gear shaft
diameter.

D

Use an inside dial indicator to measure the idler gear
inside diameter.

226RS041

D

Calculate the idler gear and idler gear shaft
clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
If the measured value exceeds the specified limit, the
idle gear and/or the idler gear shaft must be replaced.

Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041–0.074 mm (0.016–0.0029 in)
Limit: 0.150 mm (0.0059 in)

MANUAL TRANSMISSION

7B–43

Clutch Hub Spline Play

D

Set a dial indicator to the clutch hub to be measured.

226RS042

D

Move the clutch hub as far as possible to both the right
and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit, the
clutch hub must be replaced.

Clutch Hub Spline Play

 

Standard

Limit

1st–2nd

0 – 0.1 mm

0.2 mm

3rd–4th

(0 – 0.004 in)

(0.008 in)

Rev. 5th

0 – 0.2 mm

(0 – 0.008 in)

0.3 mm

(0.012 in)

Ball Bearing Play

D

Use a dial indicator to measure the ball bearing play.

Ball Bearing Play

Limit: 0.2 mm (0.008 in)

226RS043

Reassembly

1. Install center roller bearing(29) to counter gear

shaft(30).

D

Apply engine oil to the bearing inner and outer
circumferences.

D

Install the roller bearing in the proper direction.

NOTE: Check that outer race moves only in the direction
of arrow.

226RS044

2. Install front roller bearing(28) by performing the

following steps.

D

Use bearing installer to install the front roller
bearing inner race to the counter gear shaft.

D

Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.

D

Use bearing installer J–35283 to install the ring.

7B–44

MANUAL TRANSMISSION

226RS045

Legend

(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race

3. Install bearing snap ring(27) to mainshaft(26).
4. Apply engine oil to the needle bearing(25) and the 2nd

gear thrust surfaces.
Install the needle bearing(25) and the 2nd gear(24) to
the mainshaft.
The 2nd gear dog teeth must be facing the
transmission rear side.

226RS046

5. Assemble 2nd inside ring(23), 2nd outside ring(22),

and 2nd block ring(21).

D

Apply engine oil to the synchronizer ring friction
surfaces.

226RS047

Legend

(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing

6. Assemble 1st–2nd synchronizer assembly by

performing the following steps:
1. Check that the inserts(3) fit snugly into the block

ring insert grooves.

2. Check that the inserts springs(4) are fitted to the

inserts as shown in the illustration.

3. Check that the clutch hub(5) and the sleeve(6)

slide smoothly.

4. Install the synchronizer assembly to the

mainshaft.

The clutch hub face (with the heavy boss) must be
facing the 2nd gear side.