Opel Frontera UBS. Manual - part 589

MANUAL TRANSMISSION

7B–61

6. Install the counter 5th gear bearing, counter 5th

gear and reverse block ring set to the counter
gear shaft, through the 5th reverse shift arm to the
5th reverse shift rod.

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

press, install counter 5th gear spline piece.

NOTE:

D

Align the projection of the cone ring to the holes of the
5th gear spline piece.

D

Check that the gear rotates smoothly.

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8. Using thickness gauge, measure the counter 5th

gear thrust clearance.

Standard: 0.10 – 0.35mm (0.004 – 0.014 in)

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9. Select a snap ring that will allow minimum axial

play.

Mark

Thickness

A

2.80 – 2.85 (0.110 – 0.112 in)

B

2.85 – 2.90 (0.112 – 0.114 in)

C

2.90 – 2.95 (0.114 – 0.116 in)

D

2.95 – 3.00 (0.116 – 0.118 in)

E

3.00 – 3.05 (0.118 – 0.120 in)

F

3.05 – 3.10 (0.120 – 0.122 in)

G

3.10 – 3.15 (0.122 – 0.124 in)

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7B–62 MANUAL TRANSMISSION

10. Install the new snap ring.

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32. Install the shift arm bolts.

1. Install and torque the 2 shift arm bolts.

Torque: 20 N·m (2.0 kg·m/14 lb ft)

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33. Install the shift arm slotted pin.

1. Using a pin punch and a hammer, drive in the

slotted pin to the shift arm.

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34. Install the transmission case.

1. Clean up the fitting surface.

2. Apply recommended liquid gasket (THREE

BOND 1281 or equivalent), as shown.

NOTE:

D

Don’t dry the liquid gasket.

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MANUAL TRANSMISSION

7B–63

3. Stand the transmission by the wood blocks.

4. Using a plastic hammer, tap the transmission

case and attach it to the intermediate plate.

NOTE: Be careful not to add over force to bearing.

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5. Using a snap ring expander, install the front

bearing shaft snap ring (1) and counter gear shaft
bearing snap ring (2).

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6. Turn over the transmission.

35. Install the front cover.

1. Clean up the fitting surface.

2. Apply recommended liquid gasket (THREE

BOND 1281 or equivalent), as shown.

NOTE:

D

Don’t dry the liquid gasket.

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3. Clean up and dry the bolts.

4. Apply thread sealant (THREE BOND 1344 or

equivalent) to the 8 bolts.

5. Using 8 bolts, install the front cover to the

transmission case.

Torque: 17 N·m (1.7 kg·m/12 lb ft)

NOTE:

D

Tighten the all bolts evenly.

D

Be careful not to damage the oil seal.

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7B–64 MANUAL TRANSMISSION

6. Check that the top gear shaft and mainshaft

rotate.

36. Install the transfer adapter.

1. Clean up the fitting surface.

2. Apply recommended liquid gasket (THREE

BOND 1281 or equivalent), as shown.

NOTE:

D

Don’t dry the liquid gasket.

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3. Using a plastic hammer, tap the transfer adapter

and attach it to the intermediate plate.

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4. Using 10 bolts, install the transfer adapter.

Torque: 37 N·m (3.8 kg·m/27 lb ft)

NOTE:

D

Tighten the all bolts evenly.

D

Don’t damage the lip of the oil seal.

D

Install the wire clamp (9) to the transfer adapter.

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37.  Install the gear control box.

1. Align the projection of the shift lever housing to

the shaft rod groove, and install the gear control
rod.

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