Opel Frontera UBS. Manual - part 1565

7C–22

CLUTCH

Master Cylinder

Disassembled View

208RW016

Legend

(1) Master Cylinder Assembly
(2) Gasket

(3) Damper Cylinder Assembly
(4) Nut
(5) Push Rod Damper

CLUTCH

7C–23

Disassembly

(4JX1)

1. Remove damper cylinder assembly and gasket.
2. Remove push rod damper.

NOTE: The master cylinder assembly cannot be
disassembled because of point–staked rod stopper.

Inspection and Repair

Clean and inspect the removed parts.
Make necessary parts replacement if any abnormalities
such as wear, oil leaks or other damage are found through
inspection.

Reassembly

To reassemble, follow the disassembly steps in the
reverse order, noting the following points:

1. Push rod set length

RHD: 117.5 mm (4.626 in)
LHD: 119 mm (4.685 in)

2. Push rod nut torque

17 N·m (1.7 kg·m/12 Ib ft)

3. Damper cylinder torque

47 N·m (4.8 kg·m/35 Ib ft)

7C–24

CLUTCH

Slave Cylinder

Disassembled View

206RW004

Legend

(1) Cylinder Body
(2) Spring

(3) Piston and Piston Cup 
(4) Boot 
(5) Push Rod

Disassembly

1. Remove boot.
2. Remove push rod.
3. Remove piston and piston cup.
4. Remove spring.

Inspection and Repair

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

Cylinder Body

206RS003

1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it

if necessary.

CLUTCH

7C–25

Piston and Piston Cup

1. Visually inspect the disassembled piston and piston

cup for excessive wear and damage.

2. Replace the inner parts with new parts shown in the

illustration.

206RS004

3. Measure the clearance between slave cylinder wall

and piston.

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

slave cylinder assembly must be replaced. 

Standard: 0.07 mm (0.0028  in)
Limit: 0.15 mm (0.0059  in)

206RS005

Reassembly

To reassemble, follow the disassembly steps in the
reverse order, noting the following points:

1. Before installing the parts, apply a thin coat of rubber

grease.

2. Install cup in groove in piston with the lip turned to the

front of cylinder.  Use care so as not to scratch the
cylinder. 

206RS006