Opel Frontera UBS. Manual - part 2645

7B–56 MANUAL TRANSMISSION

24. Install the interlock parts.

1. Using a screwdriver and hammer, 2 new shift rod

snap rings to the 1st–2nd and 3rd–4th shift rod.

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2. Install the 3 shift detent ball and springs to the

intermediate plate.

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3. Clean up the plug hole.

4. Apply sealant to the plug threads. 

sealant: THREE BOND 1344 or equivalent

5. Using a torx socket wrench(T40), install and

torque the 4 plugs.

Torque: 19 N·m (1.9 kg·m/14 lb ft)

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25. Install mainshaft assembly.

NOTE: Coat all parts with gear oil before installing them.

1. Using a plastic hammer, tap the 5th-reverse shift

rod at the reverse shift.

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MANUAL TRANSMISSION

7B–57

2. Install the shift arm No.1 and No.2 to the

mainshaft.

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3. Using a plastic hammer, tap the intermediate

plate and install the mainshaft.  Through the shift
arm No.1 and No.2 to the shift rod.

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4. Using a snap ring expander, install the snap ring.

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5. Using a plastic hammer, tap the 5th-reverse shift

rod at the neutral shift.

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7B–58 MANUAL TRANSMISSION

26. Install the top gear shaft.

1. Align the projection of the hub No.2 with the

synchronizer ring slots, and install the top gear
shaft assembly to the mainshaft.

2. Check that the gear rotates smoothly.

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27. Install the counter gear shaft.

1. Temporarily install the counter gear shaft to the

intermediate plate.

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2. Using installer 5–8840–2552–0 (J–42796) and a

hammer, drive in the center bearing as shown.

NOTE: Outer race snap ring groove toward rear.

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Reference: Drive in the counter rear bearing
by tapping on the front end of the counter
shaft.

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MANUAL TRANSMISSION

7B–59

28. Install the reverse idle gear.

1. Install the reverse idle gear and reverse idle gear

shaft.

NOTE:

D

Insert the reverse idle gear shaft with the slot toward
rear.

D

Install the reverse idle gear with the reverse shift arm
No.2.

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29. Install the bearing plate.

1. Align the bearing plate to groove of the reverse

idle gear shaft.

Torque: 13 N·m (1.3 kg·m/113 lb in)

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30. Install the 5th gear thrust washer.

1. Install the 5th gear thrust washer pin to the

counter gear shaft.

2. Install the 5th gear thrust washer to the counter

gear shaft.

NOTE: Thrust washer must be assembled with the
chamfered face of the washer toward the front.

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31. Install the counter 5th gear.

1. Install the 3 inserts and 3 compression springs to

the reverse block ring.
Reference: Push the 3 inserts with the 3 com-
pression springs to the reverse synchronizer
ring.

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