1998 OPEL FRONTERA transmission

MANUAL TRANSMISSION7B–21
Disassembly
1. Remove the drain plug and filler plug.
1. Remove the drain plug (1) and gasket.
2. Remove the filler plug (2) and gasket.
(6VE1)
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2. Remove the clutch release bearing and shift fork.
1. Remove the clutch release bearing (3) from the
front cover.
2. Remove the split pin (4). Remove the shaft from
the under. Remove the shift fork (5).
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3. Remove the switch.
1. Remove backup light switch (6) and gasket.
2. Remove neutral switch (7) and gasket (4JX1).
3. Remove 1st and 2nd switch (8) and gasket.
(4JX1)
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4. Remove the clutch housing.
1. Remove the 9 bolts.
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7B–22MANUAL TRANSMISSION
2. Using a plastic hammer, carefully tap the clutch
housing.
(6VE1)
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5. Remove gear control box and gasket.
1. Remove the 6 bolts, gear control box and gasket.
(6VE1)
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6. Remove transfer adapter.
1. Using a hexagon wrench, remove the plug (1).
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2. Using a pin punch and hammer, drive out the
slotted spring pin (2).
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MANUAL TRANSMISSION7B–23
3. Using the M8 1.25 bolt, remove the gear control
rod and the shift lever hausing.
NOTE: Turn the M8 bolt a few times, before remove the
gear control rod.
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4. Remove the 10 bolts and clamp.
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5. Using a plastic hammer, tap the transfer adapter.
NOTE:
Be careful not to lose the pin.
Cover the mainshaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
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7. Disassemble the transfer adapter assembly.
1. Using a torx socket wrench(T40), remove the
plug.
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7B–24MANUAL TRANSMISSION
2. Using a pin punch and hammer, drive out the
slotted spring pin. Remove the reverse restrict
pin.
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3. Remove the oil receiver pipe.
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4. Remove the oil seal.
5. Using socket hexagon wrench, remove the plug.
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8. Remove the front cover.
1. Remove the 8 bolts.
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MANUAL TRANSMISSION7B–25
2. Using a plastic hammer, carefully tap the front
cover.
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9. Remove the front cover oil seal.
1. Mount the front cover through the aluminum plate
in a vise.
2. Using screwdriver, remove oil seal (1).
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10. Remove the transmission case.
1. Using a snap ring expander, remove the 2 snap
rings (1)(2).
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2. Using a plastic hammer, carefully tap the
transmission case.
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7B–26MANUAL TRANSMISSION
11. Mount the intermediate plate.
1. Mount the intermediate plate through the
aluminum plate in a vise.
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12. Remove the slotted spring pin.
1. Using a pin punch and hammer, drive out the pin
from the arm.
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13. Remove the shift arm set bolt.
1. Remove the 2 bolts from the shift arm.
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14. Remove the counter 5th gear.
1. Using 2 screwdrivers and hammer, tap out the
snap ring.
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MANUAL TRANSMISSION7B–27
2. Using remover 5–8840–2550–0 (J–42794) and
attachment 5–8840–2560–0 (J–42988), remove
the 5th gear spline piece.
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3. Remove the hub sleeve No.3, block ring set,
counter 5th gear, bearing and 5th shift arm.
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4. Remove the synchronizer pull ring, synchronizer
cone ring, and synchronizer outer ring from hub
sleeve No.3.
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5. Remove the reverse block ring from the hub
sleeve No.3. Remove the 3 inserts and 3
compression springs.
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7B–28MANUAL TRANSMISSION
15. Remove the thrust washer.
1. Remove the thrust washer from counter gear
shaft.
2. Remove the thrust washer pin from counter gear
shaft.
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16. Remove the bearing plate.
1. Remove the 4 bolts and bearing retainer.
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17. Remove the reverse idle gear.
1. Pull out the shaft foward the rear and remove the
reverse idle gear.
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18. Remove the counter gear shaft.
1. Using snap ring plier, remove counter gear shaft
center bearing snap ring.
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