Opel Frontera UBS. Manual - part 1562

7C–10

CLUTCH

5. Mark the flywheel, clutch cover and pressure plate lug

for alignment when installing. 

6. Remove the release bearing (3) from the

transmission case .

7. Remove the shift fork snap pin.
8. Remove the shift fork pin and shift fork (4) from the

front cover.

9. Remove the front cover bolts.

10. Remove the front cover (5) from the transmission

case. 

220RW088

11. Remove flywheel assembly and crankshaft bearing.

Do not remove except for replacement.

12. Use the remover 5–8840–2000–0 (J–5822) and

sliding hammer 5–8840–0019–0 (J–23907) to
remove the crankshaft bearing 

015RW053

Inspection and Repair

Make necessary correction or parts replacement if wear,
damage, or any other abnormal condition are found
through inspection.

Pressure Plate Assembly

201RS002

1. Visually check the pressure plate friction surface for

excessive wear and heat cracks.

2. If excessive wear or deep heat cracks are present,

the pressure plate must be replaced.

Pressure Plate Warpage

201RS003

CLUTCH

7C–11

1. Use a straight edge and a feeler gauge to measure

the pressure plate friction surface flatness in four
directions.

2. If any of the measured values exceeds the specified

limit, the pressure plate must be replaced. 

Pressure Plate Warpage 
Limit: 0.3 mm (0.012 in)

Clutch Cover

201RS004

1. Visually check the entire clutch cover for excessive

wear, cracking, and other damage.

2. The clutch cover must be replaced if any of these

conditions are present. 

Clutch Set Force

201RS005

1. Invert the pressure plate assembly.

2. Place a new driven plate over the pressure plate. A

metal sheet with “A” thickness of 8.3 mm (0.327 in)
may be used in place of the driven plate.

3. Compress the pressure plate assembly until the

distance “B” becomes 12 mm (0.472  in).

4. Note the pressure gauge reading.
5. If the measured value is less than the specified limit,

the pressure plate assembly must be replaced. 

Clutch Set Force
Standard: 7208 N ( 1621 lb)
Limit: 6468 N (1454 lb)

Diaphragm Spring Finger Height

201RW009

Legend

(1) Release Side

1. Place a new driven plate or a 8.3 mm (0.327 in)

spacer beneath the pressure plate.

2. Fully compress the pressure plate and diaphragm

spring.

3. There are two ways to do this.
4. Use a bench press to press down on the assembly

from the top.

5. Tighten the fixing bolts. 

NOTE: Preload on diaphragm spring finger must be 49 –
98 N (11 – 22 lb) in direction of release, when clutch cover
assembly is bolted to the flywheel. 

6. Measure the spring height from base to spring tip “A”.

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

Diaphragm Spring Finger Height
Standard: 49.9 mm – 51.9 mm (1.965 in –
2.043 in)

7C–12

CLUTCH

Driven Plate Assembly

201RW033

Legend

(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)

1. Visually check the torsion spring for looseness,

breakage, and weakening.

2. If any of these conditions are discovered, the driven

plate assembly must be replaced.

3. Visually check the facing surfaces for cracking and

excessive scorching.

4. Visually inspect the facing surfaces for the presence

of oil or grease.

5. If any of these conditions are discovered, the facing

must be cleaned or replaced.

6. Check that the driven plate moves smoothly on the

transmission top gear shaft spline.

7. Minor ridges on the top gear shaft spline may be

removed with an oil stone. 

Driven Plate Warpage

201RW034

Legend

(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)

1. Insert the clutch pilot aligner into the driven plate

splined hub.

2. The clutch pilot aligner J-24547 must be held

perfectly horizontal.

3. Set a dial indicator to the driven plate outside

circumference.

4. Slowly turn the driven plate.
5. Read the dial indicator as you turn the driven plate.
6. If the measured value exceeds the specified limit, the

driven plate assembly must be replaced. 

Driven Plate Warpage
Standard: 0.7 mm (0.028 in)
Limit: 1.0 mm (0.039 in)

CLUTCH

7C–13

Driven Plate Splined Hub Spline Wear

201RW032

Legend

(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)

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.
5. Measure the spline rotation play as you turn the

driven plate.

6. If the measured value exceeds the specified limit, the

driven plate assembly must be replaced. 

Driven Plate Splined Hub Spline Wear 
Standard: 0.5 mm (0.020 in)
Limit: 1.0 mm (0.039 in)

Rivet Head Depression

201RS010

1. Use a depth gauge or a straight edge with steel rule to

measure the rivet head depression 1 from the facing
surface 2.

2. Be sure to measure the rivet head depression on both

sides of the driven plate.

3. If the measured value is less than the specified limit,

the driven plate assembly must be replaced.

Rivet Head Depression
Standard: 

Flywheel side

Pressure plate side

6VE1

1.95mm (0.077 in)

1.95mm (0.077 in)

4JX1

1.60mm (0.063 in)

1.60mm (0.063 in)

Limit: 0.2 mm (0.008 in)