Opel Frontera UE. Manual - part 441

MANUAL TRANSMISSION

7B–37

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)

226RS024

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.

226RW215

19. Install oil seal collar(1). 

7B–38

MANUAL TRANSMISSION

Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft (MUA)

Disassmebled View

226RS026

Legend

(1) Top Gear Shaft Snap Ring
(2) Top Gear Shaft
(3) Ball Bearing
(4) Needle Bearing
(5) Top Block Ring
(6) Mainshaft Snap Ring
(7) 3rd–4th Synchronizer Assembly
(8) 3rd Block Ring
(9) 3rd Gear

(10) Needle Bearing

(11) Needle Bearing Collar

(12) Mainshaft Ball Bearing
(13) 1st Gear Thrust Bearing
(14) 1st Gear
(15) 1st Inside Ring

(16) 1st Outside Ring
(17) 1st Block Ring
(18) Needle Bearing
(19) Clutch Hub Snap Ring
(20) 1st–2nd Synchronizer Assembly
(21) 2nd Block Ring
(22) 2nd Outside Ring
(23) 2nd Inside Ring
(24) 2nd Gear
(25) Needle Bearing
(26) Mainshaft
(27) Bearing Snap Ring
(28) Front Rollar Bearing
(29) Center Roller Bearing
(30) Counter Gear Shaft

MANUAL TRANSMISSION

7B–39

Disassembly

1. Use a pair of snap ring pliers to remove the top gear

shaft snap ring(1).

2. Remove top gear shaft(2) with ball bearing(3).
3. Use a bench press and the bearing remover

5–8840–0015–0 to remove the ball bearing(3).

226RW216

4. Remove needle bearing(4) and top block ring(5),

mainshaft snap ring.

5. Use a pair of snap ring pliers to remove the mainshaft

snap ring(6).

226RS028

6. Use a bench press and the bearing remover

5–8840–0015–0 to remove the 3rd–4th synchronizer
assembly(7) as a set.
Disassemble the synchronizer assembly.

226RW217

Legend

(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts

7. Remove 3rd block ring(8), 3rd gear(9), and needle

bearing(10).

8. Remove needle bearing collar(11).
9. Use a bench press and the bearing remover

5–8840–0015–0 to remove the 1st gear(14) together
with the mainshaft ball bearing(12) and 1st gear thrust
bearing(13).

226RW218

7B–40

MANUAL TRANSMISSION

10. Disassemble 1st inside ring(15), 1st outside ring(16),

and 1st block ring(17).

11. Remove needle bearing(18).

12. Use a pair of snap ring pliers to remove the clutch hub

snap ring(19).

226RS031

13. Use a bench press and the bearing remover

5–8840–0015–0 to remove the 2nd gear(24) together
with 1st–2nd synchronizer assembly(20), 2nd block
ring(21), 2nd outside ring(22), and 2nd inside
ring(23).
Disassemble the synchronizer assembly.

226RW220

Legend

(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts

14. Remove needle bearing(25) from mainshaft(26).
15. Remove bearing snap ring(27)

16. Use a bench press and the bearing remover

5–8840–0015–0 to remove the front roller
bearing(28).

226RW219

17. Remove center roller bearing(29) from counter gear

shaft(30).

Inspection and Repair

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

Block Ring and Dog Teeth Clearance

D

Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.

226RS035

If the measured value exceeds the specified limit, the
block ring must be replaced.