Opel Frontera UE. Manual - part 1055

CLUTCH

7C–11

Pressure Plate Warpage

Use a straight edge and a feeler gauge to measure the
pressure plate friction surface flatness in four directions.

201RS038

If any of the measured values exceed the specified limit,
the pressure plate must be replaced.

Pressure Plate Warpage

Limit: 0.3mm (0.012in)

Clutch Cover

Visually inspect the entire clutch cover for excessive
wear, cracking, and other damage. The clutch cover must
be replaced if any of these conditions are present.

201RS039

Clutch Set Force

1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure plate. A

metal sheet with thickness of 7.0mm (0.276in) may
be used in place of the driven plate.

3. Compress the pressure plate assembly until the

distance becomes 4mm (0.157in).

4. Note the pressure gauge reading.

Clutch Set Force

Standard: 5488N (559 kg/1235lb)

201RY00003

Diaphragm Spring Finger Height

1. Place a 7.0mm (0.276in) spacer beneath the

pressure plate.

2. Fully compress the pressure plate and diaphragm

spring.
There are two ways to do this:

a. Use a bench press to press down on the assembly

from the top.

b. Tighten the fixing bolts.

3. Measure the spring finger height from base to spring

tip.
If the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.

Spring Finger Height

Standard: 37.5 mm – 39.5 mm (1.48 in – 1.56 in)

201RY00001

7C–12

CLUTCH

Shift Fork

1. Visually inspect the surfaces of the shift fork making

contact with the shift block.

2. Remove any minor stepping or abrasion from the shift

block with an oil stone.

3. Apply molybdenum disulfide type grease to the areas

as shown in the figure.

MUA

F07RW030

Driven Plate Assembly

1. Visually inspect the torsion spring for looseness,

breakage, and weakening.  If any of these conditions
are discovered, the driven plate assembly must be
replaced.

2. Visually inspect the facing surfaces for cracking and

excessive scorching.  Visually inspect the facing
surfaces for the presence of oil or grease.  If any of
these conditions are discovered, the facing must be
cleaned or replaced.

201RS007

3. Check that the driven plate moves smoothly on the

transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be
removed with an oil stone.

Driven Plate Warpage

1. Insert the clutch pilot aligner J–42877 (MUA) into the

driven plate splined hub.
The clutch pilot aligner must be held perfectly
horizontal.

2. Set a dial indicator to the driven plate outside

circumference.

201RS008

3. Slowly turn the driven plate.  Read the dial indicator as

you turn the driven plate.
If the measured value exceeds the specified limit, the
driven plate assembly must be replaced.

Driven Plate Warpage
Standard: 0.7 mm (0.028 in)
Limit: 1.0 mm (0.039 in)

Driven Plate Splined Hub Spline Wear

1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear

shaft spline.

3. Set a surface gauge to the driven plate outside

circumference.

4. Slowly turn the driven plate counterclockwise.

Measure the spline rotation play as you turn the
driven plate.

Driven Plate Splined Hub Spline Wear 
Standard: 0.5 mm (0.020 in)
Limit: 1.0 mm (0.039 in)

CLUTCH

7C–13

201RS009

Rivet Head Depression

Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression (1) from the facing
surface (2).
Be sure to measure the rivet head depression on both
sides of the driven plate.  If the measured value is less
than the specified limit, the facing must be replaced.

Rivet Head Depression
Standard: MIN 1.3 mm (0.051 in)
Limit: 0.2 mm (0.008 in)

201RS010

Pressure Plate Assembly

Check the cover for cracks and distortion, and the
diaphragm spring for heat distortion, loosened rivets.
Check the diaphragm spring for wear.

201RS047

Installation

1. Clean and lubricate with grease.
2. Use installer J–1522 to install crankshaft bearing (6).

X22SE

015RS078

7C–14

CLUTCH

3. Apply molybdenum disulfide type grease to the areas

as shown in the figure and install shift fork (5).

MUA

F07RW030

4. Pack the inside recess (A) of the release bearing with

grease as shown in the figure.

201RY00004

5. Install driven plate assembly by using aligner

J–42877 (MUA).

201RS049

6. Tighten the bolts holding the pressure plate assembly

(2) in the order shown in the figure.

Torque: 18N·m (1.8 kg·m/13 lb ft)

201RS050

7. Remove the aligner.

NOTE: Do not strike the aligner with a hammer to remove
it.

8. Install transmission assembly (1) to the engine.  Refer

to Transmission Installation in Manual Transmission
section.