1998 OPEL FRONTERA clutch

7B–66MANUAL TRANSMISSION
38. Install clutch housing.
1. Install the clutch housing to the transmission
case.
Torque: 36 Nꞏm (3.7 kgꞏm/27 lb ft)
NOTE: Tighten the all bolts evenly.
241RW001
39. Install the switches.
1. Install the new gasket to the 1st and 2nd switch.
2. Install the 1st and 2nd switch assembly (8).
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
3. Install the new gasket to the backup light switch.
4. Install the backup light switch assembly (6).
Torque: 44 Nꞏm (4.5 kgꞏm/33 lb ft)
5. Install the new gasket to the neutral switch.
6. Install the neutral switch (7) to the transfer
adapter (4JX1).
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
(4JX1)
220RW093
40. Install the clutch release bearing (3) and clutch shift
fork (5).
1. Apply the clutch release grease.
1. Fitting surface of the cylinder push rod.
2. Fitting surface of the release bearing hub.
3. The hole of the fork split pin (4).
2. Apply the clutch release grease.
1. The spline surface of the top gear shaft.
3. Install the clutch shift fork (5).
4. Install the snap pin.
5. Install the clutch release bearing (3) to the clutch
shift fork (5).
220RW086

7B–72MANUAL TRANSMISSION
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2550–0
(J–42794)
Gear spline pieace
remover
5–8840–2551–0
(J–42795)
Center bearing remover
5–8840–2560–0
(J–42988)
Attachment
5–8840–2552–0
(J–42796)
Counter gear shaft
center bearing installer
5–8840–2553–0
(J–42797)
Clutch hub (No.2)
installer
5–8840–2554–0
(J–42798)
Clutch hub (No.1)
installer
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2555–0
(J–42799)
Installer
5–8840–2556–0
(J–42800)
Counter gear shaft front
bearing installer
5–8840–2559–0
(J–42904)
Top gear shaft front
bearing installer
5–8840–2557–0
(J–42801)
Front rerainer oil seal
installer
5–8840–2558–0
(J–42802)
Transfer adapter oil seal
installer
5–8840–0007–0
(J–8092)
Driver handle

CLUTCH7C–1
TRANSMISSION
CLUTCH
CONTENTS
Service Precaution 7C–1. . . . . . . . . . . . . . . . . . . . . .
General Description 7C–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 7C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly 7C–9. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly and Associated Parts 7C–9. . .
Removal 7C–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C–10. . . . . . . . . . . . . . . . . .
Installation 7C–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Control 7C–17. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Control Parts 7C–17. . . . . . . . . . . . . . . . . . .
Removal 7C–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C–18. . . . . . . . . . . . . . . . . .
Installation 7C–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 7C–19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder 7C–22. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7C–22. . . . . . . . . . . . . . . . . . . .
Disassembly 7C–23. . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 7C–23. . . . . . . . . . . . . . . . . .
Reassembly 7C–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Slave Cylinder 7C–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7C–24. . . . . . . . . . . . . . . . . . . .
Disassembly 7C–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C–24. . . . . . . . . . . . . . . . . .
Reassembly 7C–25. . . . . . . . . . . . . . . . . . . . . . . . . .
Damper Cylinder 7C–26. . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7C–26. . . . . . . . . . . . . . . . . . . .
Disassembly 7C–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C–26. . . . . . . . . . . . . . . . . .
Reassembly 7C–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 7C–27. . . . . . . . . . . . .
General Specifications 7C–27. . . . . . . . . . . . . . . . .
Torque Specifications 7C–27. . . . . . . . . . . . . . . . . .
Special Tools 7C–30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFOMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastner in the
proper location. When you reolace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that requir a
replacement after removal. ISUZU will also call out
the fasteners that requir thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fastners or fastner
joint interfaces. Generally,such coatings adversely
affect the fastner torque and the joint clamping force,
and may damage the fastner. When you install
fasteners, use the correct tightening sequence and
specifications. Following these instructions can
help you avoid damage to parts and systems.

CLUTCH7C–3
Master Cylinder
(6VE1 LHD)
A07RW007
(6VE1 RHD)
A07RW066

7C–4CLUTCH
(4JX1)
A07RW067
Damper Cylinder
(Except 6VE1 LHD)
A07RS004
In order to reduce the occurrence of noises at the clutch
hydraulic system, the damper cylinder is used in theclutch hydraulic line between the master cylinder and
slave cylinder.

CLUTCH7C–5
Slave Cylinder
A07RS005
Pressure Plate Assembly
A07RS006

7C–6CLUTCH
Driven Plate Assembly
(6VE1)
A07RS007

CLUTCH7C–7
(4JX1)
A07RW045