Opel Frontera UE. Manual - part 435

MANUAL TRANSMISSION

7B–13

12. Install flywheel under cover(17).  6VD1: 3 pieces,

X22SE: 1 piece.

Torque: 8 N·m (0.8 kg·m/69 lb in)

13. Install starter(16) (6VD1).

Torque: 40 N·m (4.1 kg·m/30 lb ft)

14. Install third crossmember(15).

Torque: 50 N·m (5.1 kg·m/37 lb ft)

15. Install engine rear mount nuts(14).

Torque: 40 N·m (4.1 kg·m/30 lb ft)

Remove the transmission jack from transmission
side.

16. Apply grease to top hole portion of the shift fork.

Install slave cylinder(12) and flexible hose fixing
bracket (X22SE).

Torque: 43 N·m (4.4 kg·m/32 lb ft)

220RS007

Legend

(1) Apply Grease

17. Install clutch dust covers(13) to clutch housing

(6VD1).

Torque: 6 N·m (0.6 kg·m/52 lb in)

18. Connect transmission harness connectors and clip.

Connector: transfer switch, 2–4 actuator, car speed
sensor, 1–2 indicator switch (6VD1) and 3–4 indicator
switch (6VD1).

19. Install bracket and transmission harness clamps(10)

to the transmission case.

20. Install harness heat protector(11) (6VD1).
21. Connect fuel pipe to transmission side.

220RW046

220RW047

7B–14

MANUAL TRANSMISSION

22. Install center exhaust pipe(9) (6VD1).

Torque: 43 N·m (4.4 kg·m/32 lb ft)

150RX009

23. Tighten the exhaust pipe nuts at the manifold

(X22SE).

Torque: 43 N·m (4.4 kg·m/32 lb ft)

24. Install front(8) and rear propeller shaft(7).

Torque: 63 N·m (6.4 kg·m/46 lb ft)

25. Install transfer protector(6).

Lower the vehicle.

150RX010

26. Install gear control lever(5) and transfer control

lever(5).

27. Install grommet assembly(4).
28. Install center console(3), rear console and lower

cluster assembly.

29. Install transfer control lever knob(2) and gear control

lever knob(1).

30. Connect battery ground cable.
31. Replenish engine coolant (X22SE).

MANUAL TRANSMISSION

7B–15

Transmission Case and Transfer Case

Major Component (MUA)

220RX005

Legend

(1) Clutch Release Bearing
(2) Shift Fork
(3) Fulcrum Bridge
(4) Front Cover (with Oil Seal)
(5) Counter Front Bearing Snap Ring
(6) Top Gear Bearing Snap Ring
(7) Speedometer Sensor and Speedometer Driven

Gear

(8) Front Companion Flange
(9) Rear Companion Flange

(10) Gear Control Box Assembly

(11) 2WD–4WD Actuator Assembly

(12) Transfer Rear Case Assembly
(13) Detent, Shift Arm, and Interlock Pin
(14) Bearing Snap Ring

(15) Ball Bearing
(16) Lock Nut
(17) High-Low Clutch Hub and Sleeve
(18) Transfer Input Gear
(19) Needle Bearing
(20) Bearing Collar
(21) Ball
(22) Plate
(23) Bearing Snap Ring
(24) Front Output Gear Assembly
(25) Bearing Snap Ring
(26) Counter Gear Assembly
(27) 1–2 and 3–4 Indicator Switch, Pin, and Ball
(28) Transfer Case Assembly
(29) Intermediate Plate with Gear Assembly
(30) Transmission Case

7B–16

MANUAL TRANSMISSION

Disassembly

1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case

and transfer case and drain the lubricant.

3. Remove the clutch release bearing(1) from the

transmission case.

201RS020

4. Remove the snap pin (6VD1).

Remove the shift fork pin (6VD1) and shift fork(2)
from the fulcrum bridge(3) (6VD1).

201RS021

5. Remove the fulcrum bridge bolts (6VD1).

D

Remove the fulcrum bridge(3) (6VD1) from the
transmission case.

Remove the front cover(4) and gasket from the
transmission case.

201RS022

6. Remove counter front bearing snap ring(5) and top

gear bearing snap ring(6).
Use a pair of snap ring pliers to remove the snap ring.

226RS001