Opel Frontera UE. Manual - part 1615

MANUAL TRANSMISSION

7B–9

5. Tighten the transmission nut and bolts as shown in

the figure.

225RX004

6. Apply a force of 59 – 78 N (6.0 – 8.0 kg/

13.2 – 17.6 lb) to the tip of the shift fork in the
direction of the transmission to engage the clutch
pressure plate and release bearing.

NOTE: A click sound is heard when the release bearing
and the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine side while applying
a force of about 25 N (2.5 kg/5.5 lb).  If the shift fork will
not move, then they are securely engaged.

220RS006

SECTION

7B–10

MANUAL TRANSMISSION

7. Install flywheel under cover(16).

Torque: 8 N·m (0.8 kg·m/69 lb in)

8. Install starter(15).

Torque: 40 N·m (4.1 kg·m/30 lb ft)

9. Install third crossmember(14).

Torque: 50 N·m (5.1 kg·m/37 lb ft)

10. Install engine rear mount nuts(13).

Torque: 40 N·m (4.1 kg·m/30 lb ft)

Remove the transmission jack from transmission
side.

11. Install clutch dust covers(12) to clutch housing.

Torque: 6 N·m (0.6 kg·m/52 lb in)

12. Connect transmission harness connectors and clip.

Connector: transfer switch, 2–4 actuator, car speed
sensor.

13. Install bracket and transmission harness clamps(10)

to the transmission case.

14. Install harness heat protector(11).
15. Connect fuel pipe to transmission side.

220RW046

220RW047

16. Install center exhaust pipe(9).

Torque: 43 N·m (4.4 kg·m/32 lb ft)

150RX009

17. Install front(8) and rear propeller shaft(7).

Torque: 63 N·m (6.4 kg·m/46 lb ft)

18. Install transfer protector(6).

Lower the vehicle.

150RX010

19. Install gear control lever(5) and transfer control

lever(5).

20. Install grommet assembly(4).
21. Install center console(3), rear console and lower

cluster assembly.

22. Install transfer control lever knob(2) and gear control

lever knob(1).

23. Connect battery ground cable.

SECTION

MANUAL TRANSMISSION

7B–11

Transmission Case and Transfer Case

Major Component (MUA)

220R100003

Legend

(1) Clutch Release Bearing
(2) Shift Fork
(3) Fulcrum Bridge
(4) Front Cover (with Oil Seal)
(5) Counter Front Bearing Snap Ring
(6) Top Gear Bearing Snap Ring
(7) Speedometer Sensor and Speedometer Driven

Gear

(8) Front Companion Flange
(9) Rear Companion Flange

(10) Gear Control Box Assembly

(11) 2WD–4WD Actuator Assembly

(12) Transfer Rear Case Assembly
(13) Detent, Shift Arm, and Interlock Pin
(14) Bearing Snap Ring

(15) Ball Bearing
(16) Lock Nut
(17) High-Low Clutch Hub and Sleeve
(18) Transfer Input Gear
(19) Needle Bearing
(20) Bearing Collar
(21) Ball
(22) Plate
(23) Bearing Snap Ring
(24) Front Output Gear Assembly
(25) Bearing Snap Ring
(26) Counter Gear Assembly
(27) Plug and Gasket
(28) Transfer Case Assembly
(29) Intermediate Plate with Gear Assembly
(30) Transmission Case

SECTION

7B–12

MANUAL TRANSMISSION

Disassembly

1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case

and transfer case and drain the lubricant.

3. Remove the clutch release bearing(1) from the

transmission case.

201RS020

4. Remove the snap pin.

Remove the shift fork pin and shift fork(2) from the
fulcrum bridge(3).

201RS021

5. Remove the fulcrum bridge bolts.

D

Remove the fulcrum bridge(3) from the
transmission case.

Remove the front cover(4) and gasket from the
transmission case.

201RS022

6. Remove counter front bearing snap ring(5) and top

gear bearing snap ring(6).
Use a pair of snap ring pliers to remove the snap ring.

226RS001

SECTION