Opel Frontera UE. Manual - part 1620

MANUAL TRANSMISSION

7B–29

7. Mesh the 1st–2nd and 3rd–4th synchronizers with

both the 1st and 3rd gears (double engagement).

226RS015

This will prevent the mainshaft from turning.

8. Install the new mainshaft hub nut(19).

Use the mainshaft nut wrench 5–8840–2156–0 to
tighten the mainshaft nut(19) to the specified torque.

Torque: 137 N·m (14.0 kg·m/101 lb ft)

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9. Use a punch to stake the mainshaft nut at one spot.

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10. Install needle bearing(18), 5th block ring(17), and 5th

gear(16).

11. Apply engine oil to the counter reverse gear(15) and

the reverse gear(22).
Install the counter reverse gear(15) to the counter
shaft.
The reverse gear projection must be facing the
intermediate plate.

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SECTION

7B–30

MANUAL TRANSMISSION

12. Install the counter 5th gear(14) to the transmission.

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13. Install ball bearing(13) and bearing snap ring by

performing the following steps:

D

Select the snap ring(12) which will provide the
minimum clearance between the ball bearing and
the snap ring.

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D

There are six snap ring sizes available.
The snap rings are color-coded to indicate their
thickness.

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Ball Bearing and Snap Ring Clearance

Standard: 0–0.15 mm (0–0.0059 in)

Snap Ring Availability

Thickness

Color Coding

1.1 mm (0.043 in)

White

1.2 mm (0.047 in)

Yellow

1.3 mm (0.051 in)

Blue

1.4 mm (0.055 in)

Pink

1.5 mm (0.059 in)

Green

1.6 mm (0.063 in)

Brown

D

Use a pair of snap ring pliers to install the snap
ring(12) to the counter gear shaft.
The snap ring must be fully inserted into the counter
gear shaft snap ring groove.

14. Assemble reverse idler shaft(11), reverse idler

gear(10), thrust washer(9), and idle shaft pin(8) into
reverse idler gear assembly(7).

15. Select reverse idler gear snap ring(6) which will

provide the minimum clearance between the
intermediate plate(26) and the snap ring(6).

SECTION

MANUAL TRANSMISSION

7B–31

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D

There are three snap ring sizes available.
The snap rings are color-coded to indicate their
thickness.

Intermediate Plate and Snap Ring Clearance

Standard: 0 – 0.15 mm (0 – 0.0059 in)

Snap Ring Availability

Thickness

Color Coding

1.2 mm (0.047 in)

White

1.3 mm (0.051 in)

Yellow

1.4 mm (0.055 in)

Blue

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D

Use a pair of snap ring pliers to install the snap ring
to the reverse idler shaft.
The snap ring must be fully inserted into the reverse
idler shaft snap ring groove.

16. Install thrust washer and lock ball(5) by performing

the following steps:

D

Use a thickness gauge to measure the clearance
between the 5th gear and the thrust washer.

5th Gear and Thrust Washer Clearance

Standard: 0.10 – 0.25 mm (0.004 – 0.010 in)

D

Measure clearance “A” as shown in the figure.

226RS023

D

Select appropriate thrust washer from chart.

D

There are four thrust washer sizes available.

D

The thrust washers are color coded to indicate their
thickness.

SECTION

7B–32

MANUAL TRANSMISSION

Thrust Washer Availability

Thickness

mm (in)

Color

Coding

A mm (in)

Clearance

mm (in)

7.9 (0.311)

White

8.05–8.1

(0.317–0.319)

0.15–0.25

(0.006–0.010)

8.0 (0.315)

Yellow

8.1–8.2

(0.319–0.323)

0.1–0.25

(0.004–0.010)

8.1 (0.319)

Green

8.2–8.3

(0.323–0.327)

0.1–0.25

(0.004–0.010)

8.2 (0.323)

Bluen

8.3–8.36

(0.327–0.329)

0.1–0.21

(0.004–0.008)

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D

Apply grease to the thrust washer and the lock ball.

D

Install the thrust washer and the lock ball.

17. Install thrust plate(4) and retainer(3).

18. Apply engine oil to the bearing inner and outer

circumference. 
Use the installer 5–8840–2159–0 to install the ball
bearing(2) to the mainshaft in proper direction.

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19. Install oil seal collar(1). 

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