Opel Frontera UE. Manual - part 438

MANUAL TRANSMISSION

7B–25

Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Inter-

lock Pin (MUA)

Disassembled View

220RS010

Legend

(1) Detent Spring Plate and Gasket
(2) Detent Spring
(3) Detent Ball
(4) Spring
(5) Rev–5th Shift Rod
(6) Rev–5th Shift Arm and Reverse Inhibitor

(7) 1st–2nd Shift Rod
(8) 3rd–4th Shift Rod
(9) 3rd–4th Shift Arm

(10) 1st–2nd Shift Arm

(11) Interlock Pin

(12) Intermediate Plate and Gear Assembly

7B–26

MANUAL TRANSMISSION

Disassembly

1. Remove detent spring plate and gasket(1), detent

spring(2) and detent ball(3).
Use a magnetic hand to remove the detent balls from
the intermediate plate.

220RS011

2. Remove spring(4).
3. Remove rev–5th shift rod(5), and rev–5th shift arm

and reverse inhibitor(6).
Remove 1st–2nd shift rod(7), 3rd–4th shift rod(8),
3rd–4th shift arm(9), and 1st–2nd shift arm (10).

D

Hold a round bar against the shift rod end.

230RS003

D

Use a spring pin remover to remove the shift arm
spring pins from the shift arms and the shift rods.

230RS004

D

Move the 3rd–4th shift rod forward.

230RS005

D

Remove the rev–5th, 1st–2nd and 3rd–4th shifter
rods carefully.  Interlock pins are located between
the shifter rods in the intermediate plate.

4. Remove interlock pin(11) from intermediate plate and

gear assembly(12).

MANUAL TRANSMISSION

7B–27

Inspection and Repair

Make the necessary adjustments, and part replacements
if excessive wear or damage is discovered during
inspection.

Shift Arm Thickness

D

Use a micrometer to measure the shift arm thickness.
If the measured value is less than the specified limit,
the shift arm must be replaced.

Shift Arm Thickness

 

Standard

Limit

1st–2nd

9.60–9.85 mm

(0.378–0.388 in)

9.0 mm

3rd–4th

9.60–9.80 mm

9.0 mm

(0.354 in)

Rev.5th

(0.378–0.386 in)

230RS006

Detent Spring Free Length

D

Use a vernier caliper to measure the detent spring
free length.
If the measured value is less than the specified limit,
the detent spring must be replaced.

Detent Spring Free Length

Standard

Limit

26.8 mm (1.06 in)

26.2 mm (1.03 in)

220RS012

Detent Spring Tension

D

Use a spring tester to measure the valve spring
tension.
If the measured value is less than the specified limit,
the detent spring must be replaced.

Detent Spring Tension

Compressed height

Standard

20 mm (0.787 in)

87.2 – 97.1 N

(8.9 – 9.9 kg/

19.6 – 21.8 lb)

220RS013

7B–28

MANUAL TRANSMISSION

Reassembly

1. Install 1st–2nd shift arm(10) and 3rd–4th shift arm(9)

to intermediate plate and gear assembly(12).

2. Install 3rd–4th shift rod(8) and 1st–2nd shift rod(7).

D

Install the interlock pin(11) to the shift rod.

D

Install the shift rod together with the interlock pin to
the intermediate plate.
Do not allow the interlock pin to fall from the shift
rod.

D

Hold a round bar against the shift rod end lower face
to protect it against damage.

D

Install a new spring pin.
Never reinstall the used spring pin.

230RS007

3. Install rev–5th shift arm and reverse inhibitor(6) and

rev–5th shift rod(5).

D

Apply oil to the reverse inhibitor inner surface.

D

Install the interlock pin(11) to the shift rod.

D

Install the shift rod together with the interlock pin to
the intermediate plate.
Do not allow the interlock pin to fall from the shift
rod.

D

Hold a round bar against the shift rod end lower face
to protect it against damage.

D

Install a new spring pin.
Never reinstall the used spring pin.

4. Install spring(4).
5. Put detent balls(3) in the intermediate plate holes.

D

Apply oil to the detent balls.

6. Install detent springs(2) and detent spring plate and

gasket(1).

D

Install a new gasket and the detent spring plate.

D

Tighten the detent spring plate bolts to the specified
torque.

Torque: 20 N·m (2.0 kg·m/ 14 lb ft)

220RS030

Legend

(1) Warped