Opel Frontera UBS. Manual - part 2632

7B–4

MANUAL TRANSMISSION

Diagnosis

Condition

Possible cause

Correction

Abnormal noise

Flywheel pilot bearing worn

Replace

Bearings worn or broken (Mainshaft,
counter shaft, and transfer shaft)

Replace

Gear tooth contact surfaces worn or
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)

Replace

Splines worn (Mainshaft,
synchronizer clutch hub)

Replace

Gear or bearing thrust face seized

Replace

Lack of backlash between meshing
gears

Replace

Hard Shifting

Improper clutch pedal free play

Readjust

Change lever sliding portions worn

Repair or replace
Regrease

Shift block, shift rod and/or control
box sliding faces worn

Replace

Shift arm and synchronizer sleeve
groove worn

Replace worn parts

Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)

Replace worn parts

Synchronizer parts worn

Replace

Walking or Jumping out of gear

Detent ball worn

Replace

Detent spring weakened or broken

Replace

Shift rod and/or control box sliding
faces worn

Replace

Shift arm and synchronizer sleeve
groove worn

Replace worn parts

Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)

Replace worn parts

Bearings worn or broken

Replace

Splines worn (Mainshaft,
synchronizer hub)

Replace

Synchronizer spring weakened or
broken

Replace

Oil leakage

Loose drain plug(s) and/or filler
plug(s)

Tighten
Replenish oil

Defective or improperly installed
gasket(s)

Replace

Oil seal worn or scratched

Replace

MANUAL TRANSMISSION

7B–5

Manual Transmission Assembly

Transmission and Associated Parts

220RW108

Legend

(1) Gear Control Lever and Knob
(2) Transfer Control Lever and Knob
(3) Front Console Assembly
(4) Grommet Assembly
(5) Transfer Protector
(6) Rear Propeller Shaft
(7) Front Propeller Shaft
(8) Exhaust Pipe
(9) Backup Lamp, 4WD Indicator, and 1–2

Indicator Switch Harness Connector

(10) Speedometer Sensor and 2WD–4WD Actuator

Harness Connector

(11) Slave Cylinder Heat Protector

(12) Harness Heat Protector
(13) Slave Cylinder
(14) Dust Cover
(15) Engine Rear Mount Nut
(16) Engine Rear Mount Bolt
(17) Engine Rear Mount
(18) Third Crossmember
(19) Flywheel Under Cover
(20) Transmission Retaining Bolt
(21) Transmission Assembly with Transfer Case

7B–6

MANUAL TRANSMISSION

Removal

NOTE: Before remove the transmission and transfer
assembly from the vehicle, change the transfer mode to
2WD using push button on dash panel.

1. Remove engine hood.
2. Disconnect battery ground cable.
3. Remove the gear control lever knob.
4. Remove the front console assembly.
5. Remove the grommet assembly.
6. Remove the transmission control lever and transfer

control lever.

235RW014

7. Raise and support the vehicle with suitable jack

stand.

8. Remove transfer protector.
9. Remove the rear propeller shaft.

NOTE: Apply alignment marks on the flange at the both
front and rear side.

(4JX1)

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10. Remove the front propeller shaft.

NOTE: Apply alignment marks on the flange at both the
front and rear sides.

401RS003

11. Disconnect two oxygen sensor connectors from the

transmission harness (6VE1).

12. Remove the front and 3 way exhaust pipe (6VE1).

Remove the exhaust pipe with catalytic converter
(4JX1).

(4JX1)

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MANUAL TRANSMISSION

7B–7

13. Disconnect the backup lamp switch, 4WD indicator

switch and 1–2 indicator switch harness connectors.

826RW023

14. Disconnect the speedometer sensor and 2WD-4WD

actuator harness connectors.

826RW024