Opel Frontera UBS. Manual - part 582

MANUAL TRANSMISSION

7B–33

4. Using bearing separator 5–8840–0015–0

(J–22912–01) and a press, remove the following
parts.

1. 5th gear (1).

2. Mainshaft bearing (2).

3. 1st gear thrust washer (3).

4. 1st gear (4).

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5. Remove following parts from mainshaft.

1. Synchronizer assembly (1).

2. 1st gear thrust washer pin (3).

3. 1st gear needle roller bearing (4).

4. 1st gear bearing spacer (2).

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6. Using 2 screwdrivers and hammer, tap out snap

ring.

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7. Using bearing separator 5–8840–0015–0

(J–22912–01) and a press, remove the following
parts.

1. Clutch hub No.1 assembly (1).

2. Synchronizer assembly (2).

3. 2nd gear (3).

4. 2nd gear needle roller bearing (4).

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7B–34 MANUAL TRANSMISSION

8. Remove the reverse gear from clutch hub No.1.

9. Remove the 3 inserts and 3 compression springs.

D

When removing the inserts, push the insert
spring with a screwdriver.

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10. Remove the snap ring.

NOTE: Don’t damage the bearing surface.

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11. Using a press, remove following parts.

1. Clutch hub No.2 assembly (1).

2. 3rd block ring (2).

3. 3rd gear (3).

4. 3rd gear needle roller bearing (4).

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12. Using screwdriver, remove the 2 insert springs,

hub sleeve No.2, clutch hub No.2 and 3 inserts.

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MANUAL TRANSMISSION

7B–35

24. Remove the shift parts and interlock parts.

1. Mount the intermediate plate through the

aluminum plate in a vise.

2. Using a plastic hammer, tap the 5th shift rod on

the neutral.

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3. Using a torx socket wrench(T40), remove the 4

plugs.

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4. Using a magnetic finger, remove 3 springs and

balls.

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5. Using 2 screwdrivers and a hammer, remove 2

snap rings from each shift fork rod.

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7B–36 MANUAL TRANSMISSION

6. Pull out the 3rd–4th shift rod at the rear.

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7. Using a magnetic finger, remove the interlock pin

and straight pin.

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8. Pull out the 1st–2nd shift rod at the rear.

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9. Using a magnetic finger, remove the interlock pin.

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