Opel Frontera UBS. Manual - part 2641

7B–40 MANUAL TRANSMISSION

3. Reverse block ring set.

1. Using a thickness gauge, measure the clearance

between the counter 5th gear spline piece and
reverse block ring.

Standard: 0.7 – 1.7 mm (0.028 – 0.067 in)

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4. Reverse idle gear and reverse idle gear shaft.

1. Mount the reverse idle gear and reverse idle gear

shaft in a vise.

2. Using a dial indicator, measure the reverse idle

gear radial clearance.

Standard: 0.040 – 0.082 mm (0.0016 – 0.0032 in)

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3. If the clearance exceeds the maximum, measure

the gear inside diameter and shaft diameter.

Standard
Shaft Diameter: 23.979 – 24.000 mm
(0.94405 – 0.94488 in)
Gear Diameter: 24.040 – 24.061 mm
(0.94645 – 0.94728 in)

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5. Reverse shift arm No.2 thrust clearance.

1. Using a thickness gauge, measure the clearance

between the reverse idle gear and shift arm No.2.

Standard: 0.05 – 0.35 mm (0.002 – 0.014 in)

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MANUAL TRANSMISSION

7B–41

Reassembly

1. Install the top gear shaft assembly.

1. Using installer 5–8840–2559–0 (J–42904) and a

press, install a new bearing.

NOTE: Outer race snap ring groove (1) toward front.

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2. Select a snap ring that will allow minimum axial

play.

Mark

Thickness

A

2.10 – 2.15 mm (0.083 – 0.085 in)

B

2.15 – 2.20 mm (0.085 – 0.087 in)

C

2.20 – 2.25 mm (0.087 – 0.089 in)

D

2.25 – 2.30 mm (0.089 – 0.091 in)

E

2.30 – 2.35 mm (0.091 – 0.093 in)

F

2.35 – 2.40 mm (0.093 – 0.095 in)

G

2.40 – 2.45 mm (0.095 – 0.097 in)

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3. Using a snap ring expander, install the new snap

ring.

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4. Install the 4th block ring.

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7B–42 MANUAL TRANSMISSION

5. Using a thickness gauge, measure the clearance

between the 4th block ring back and gear spline
end.

Standard: 0.75 – 1.65 mm (0.030 – 0.065 in)

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6. Check the braking effect of the block ring.  Turn

the block ring in one direction while pushing it to
the gear cone.  Check that the ring locks.  If it does
not lock, replace the block ring.

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7. Install the needle roller bearing.

2. Reassemble the mainshaft assembly.

NOTE: Apply all parts with engine oil before installing
them.

3. Inspect block ring

1. Using a thickness gauge, measure the clearance

between the synchronizer ring back and gear
spline end.

Gear

Standard Clearanse

1st

0.80 – 1.60 mm (0.032 – 0.063 in)

2nd

0.65 – 1.75 mm (0.026 – 0.069 in)

3rd

0.75 – 1.65 mm (0.030 – 0.065 in)

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2. Turn the synchronizer ring in one direction while

pushing it to the gear cone.  Check that the ring
locks.

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MANUAL TRANSMISSION

7B–43

4. Inspect hub sleeve and shift arm.

1st–2nd shift arm

1. Using a vernier caliper, measure center groove of

the 1st–2nd shift arm.

Reference: 5.28 mm (0.208 in)

2. Using a vernier caliper, measure flange of the

reverse gear.  Calculate the clearance between
the reverse gear and shift arm.

Reference: Reverse gear flange thickness 5.0
mm. (0.197 in)

Standard: 0.15 – 0.41 mm (0.006 – 0.016 in)

226RW093

3rd–4th shift arm

1. Using a vernier caliper, measure tip of the shift

arm thickness.

Reference: 10.0mm (0.39 in)

2. Using a vernier caliper, measure center groove of

the hub sleeve No.2.   Calculate the clearance
between the hub sleeve No.2 and shift arm.

Reference: Center groove dimension 10.2 mm
(0.402 in)

Standard: 0.15 – 0.35 mm (0.006 – 0.014 in)

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5. Inspect clutch hub and hub sleeve.

1. Check for wear or damage.

2. Install the hub sleeve to the clutch hub, and check

sliding smoothly.

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6. Inspect gear inside diameter.

1. Using a inside dial indicator, measure the gear

inside diameter.

Gear

Standard Diameter

1st

46.015 – 46.040 mm (1.8116 – 1.8126 in)

2nd

53.015 – 53.040 mm (2.0872 – 2.0882 in)

3rd

44.015 – 44.040 mm (1.7329 – 1.7339 in)