Opel Frontera UE. Manual - part 1057

CLUTCH

7C–19

Driven Plate Warpage

1. Insert the clutch pilot aligner J–24547 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.

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: 0.7mm (0.028in)
Limit: 1.0mm (0.039in)

201RS008

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

Driven Plate Warpage
Standard: 0.5mm (0.020in)
Limit: 1.0mm (0.039in)

201RS009

Rivet Head Depression

D

Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression (1) from the facing
surface (2).

D

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 driven plate assembly
must be replaced.

Rivet Head Depression

Standard

Limit

Fly wheel side

1.2–1.8mm

(0.047–0.071in)

0.2mm

Pressure plate
side

1.6–2.2mm

(0.062–0.087in)

(0.008in)

201RS010

7C–20

CLUTCH

Release Bearing

D

Visually check the release bearing for excessive play,
noise and breakage. If any of these conditions are
discovered, the release bearing must be replaced.

201RS011

D

When replacing the release bearing (4), replace both
the wedge collar (10) and wire ring (11) at the same
time.

201RS012

Legend

(2) Pressure Plate Assembly
(4) Release Bearing

(10) Wedge collar

(11) Wire Ring

Wedge Collar (10)

D

Visually check the surfaces of the wedge collar
making contact with the release bearing for excessive
wear and damage.

D

Replace exhibiting excessive wear or damage.

201RS013

Shift Fork

D

Visually check the surfaces of the shift fork making
contact with the release bearing for excessive wear
and damage.

D

Remove any minor stepping or abrasion from shift
fork with an oil stone.  Replace exhibiting excessive
wear or damage.

201RS014

CLUTCH

7C–21

Installation

1. Clean and lubricate with grease.
2. Use the installer 5–8840–0125–0 and driver handle

5–8840–0007–0 to install the crankshaft bearing (7).

015RW054

3. Install the fulcrum bridge (6) to the transmission case.

Tighten three fulcrum bridge bolts to the specified
torque.

Torque: 38 N·m (28 lb ft)

201RS026

4. Apply molybdenum disulfide type grease to the pin

hole inner circumferences and thrust surfaces.
Attach the shift fork (5) to the fulcrum bridge (6) and
insert the pin from below of the fulcrum bridge.  Install
the washer and snap pin.

201RS018

5. Apply molybdenum disulfide type grease to the areas

shown in the figure.

201RW012

7C–22

CLUTCH

Install the release bearing (4) in the proper direction.

NOTE: Ensure release bearing is properly positioned
during installation, as shown in the figure.

201RS019

6. Use the pilot aligner 5–85253–001–0 to install the

driven plate assembly (3).

201RX004

7. Tighten the bolts holding the pressure plate assembly

(2) in the order shown in the figure.

201RS017

Torque: 18 N·m (1.8 kg·m/13 lb ft)

8. Remove the aligner.

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

9. Install transmission assembly to the engine.