Opel Frontera UBS. Manual - part 585

MANUAL TRANSMISSION

7B–45

8. Install 3rd gear.

1. Install the 3rd gear needle bearing, 3rd gear and

3rd block ring to the mainshaft.

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9. Install the clutch hub No.2.

1. Install the clutch hub No.2 and hub sleeve No.2.

NOTE: Be careful the direction of the clutch hub No.2, as
shown.

2. Using a screwdriver, install 3 inserts and 2

springs.

NOTE: Position the insert springs so that their end gaps
are not in line.

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3. Using installer 5–8840–2553–0 (J–42797) and a

press, install the clutch nob No.2 and hub sleeve
No.2 to the mainshaft.

NOTE:

D

Align the brock ring slots with the inserts.

D

Check that the gear rotates smoothly.

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4. Select a snap ring that will allow minimum axial

play.

Mark

Thickness

A

1.80 – 1.85 mm (0.071 – 0.073 in)

B

1.85 – 1.90 mm (0.073 – 0.075 in)

C

1.90 – 1.95 mm (0.075 – 0.077 in)

D

1.95 – 2.00 mm (0.077 – 0.079 in)

E

2.00 – 2.05 mm (0.079 – 0.081 in)

F

2.05 – 2.10 mm (0.081 – 0.083 in)

G

2.10 – 2.15 mm (0.083 – 0.085 in)

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7B–46 MANUAL TRANSMISSION

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

ring.

NOTE: Be careful not to damage the bearing surface.

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6. Using a thickness gauge, inspect the 3rd gear

thrust clearance.

Standard: 0.10 – 0.25mm (0.004 – 0.010 in)

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10. Install the 2nd gear.

1. Install the synchronizer ring set No.1 to the 2nd

gear.

NOTE: Align the nail of middle ring with gear spline slots.

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2. Install the needle roller bearing, 2nd gear and 2nd

gear block ring set to the mainshaft.

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MANUAL TRANSMISSION

7B–47

11. Install the clutch hub No.1.

1. Install the 3 inserts and 3 insert springs to the

clutch hub No.1.
Reference:  While pushing the insert spring
with a screwdriver, install the inserts.

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2. Install the clutch hub No.1 to the reverse gear.

NOTE: Check the clutch hub No.1 installing direction, as
shown.

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3. Using installer 5–8840–2554–0 (J–42798) and a

press, install the hub No.1 by retaining the
reverse gear.

NOTE:

D

Align the projection of inner ring with hub No.1 slots.

D

Check that the gear rotates smoothly.

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4. Select a snap ring that will allow minimum axial

play.

Mark

Thickness

A

2.30 – 2.35 mm (0.091 – 0.093 in)

B

2.35 – 2.40 mm (0.093 – 0.095 in)

C

2.40 – 2.45 mm (0.095 – 0.097 in)

D

2.45 – 2.50 mm (0.097 – 0.098 in)

E

2.50 – 2.55 mm (0.098 – 0.100 in)

F

2.55 – 2.60 mm (0.100 – 0.102 in)

G

2.60 – 2.65 mm (0.102 – 0.104 in)

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7B–48 MANUAL TRANSMISSION

5. Using a screwdriver and hammer, install the snap

ring.

NOTE: Be careful not to damage the bearing surface.

6. Check that the gear rotates smoothly.

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7. Using a dial indicator, measure the 2nd gear

thrust clearance.

Standard: 0.10 – 0.25mm (0.004 – 0.010 in)

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12. Install the 1st gear.

1. Install the following parts:

1. 1st gear bearing spacer (4).
2. 1st gear needle roller bearing (3).
3. Synchronizer assembly (2).
4. 1st gear (1).

NOTE:

D

Align the projection of inner ring with hub No.1 slots.

D

Check that the gear rotates smoothly.

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2. Install the 1st gear thrust washer pin and 1st gear

thrust washer to the mainshaft.

NOTE: Align the straight pin with the thrust washer slot.

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