1998 OPEL FRONTERA transmission

7C–12CLUTCH
Driven Plate Assembly
201RW033
Legend
(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)
1. Visually check the torsion spring for looseness,
breakage, and weakening.
2. If any of these conditions are discovered, the driven
plate assembly must be replaced.
3. Visually check the facing surfaces for cracking and
excessive scorching.
4. Visually inspect the facing surfaces for the presence
of oil or grease.
5. If any of these conditions are discovered, the facing
must be cleaned or replaced.
6. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
7. Minor ridges on the top gear shaft spline may be
removed with an oil stone.
Driven Plate Warpage
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Legend
(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)
1. Insert the clutch pilot aligner into the driven plate
splined hub.
2. The clutch pilot aligner J-24547 must be held
perfectly horizontal.
3. Set a dial indicator to the driven plate outside
circumference.
4. Slowly turn the driven plate.
5. Read the dial indicator as you turn the driven plate.
6. If the measured value exceeds the specified limit, the
driven plate assembly must be replaced.
Driven Plate Warpage
Standard: 0.7 mm (0.028 in)
Limit: 1.0 mm (0.039 in)

CLUTCH7C–13
Driven Plate Splined Hub Spline Wear
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Legend
(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear
shaft spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
5. Measure the spline rotation play as you turn the
driven plate.
6. If the measured value exceeds the specified limit, the
driven plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear
Standard: 0.5 mm (0.020 in)
Limit: 1.0 mm (0.039 in)
Rivet Head Depression
201RS010
1. Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression 1 from the facing
surface 2.
2. Be sure to measure the rivet head depression on both
sides of the driven plate.
3. If the measured value is less than the specified limit,
the driven plate assembly must be replaced.
Rivet Head Depression
Standard:
Flywheel sidePressure plate side
6VE11.95mm (0.077 in)1.95mm (0.077 in)
4JX11.60mm (0.063 in)1.60mm (0.063 in)
Limit: 0.2 mm (0.008 in)

CLUTCH7C–15
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install flywheel assembly and crankshaft bearing.
Use the installer 5-8840-0125-0 (J-26516-A) and
driver handle 5-8840-0007-0 (J-8092) to install the
crankshaft bearing then clean and lubricate with
grease.
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2. Install new flywheel fixing bolts in the order illustrated
and tighten them to the specified torque.
Torque:
6VE1: 54 Nꞏm (5.5 kgꞏm/40 lb ft)
4JX1: 60 Nꞏm (6.1 kgꞏm/44 lb ft)+60
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
015RS047
3. Install the front cover (5) to the transmission case.
4. Tighten eight front cover bolts to the specified torque.
Torque: 17 Nꞏm (1.7 kgꞏm/12 lb ft)
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5. Apply molybednum disulfide type grease to the pin
hole inner circumferences and thrust surfaces.
6. Attach the shift fork to the front cover and insert the
pin from below of the front cover.
7. Install the washer and snap pin.
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7C–16CLUTCH
8. Apply molybdenum disulfide type grease to the areas
shown in illustration.
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9. Install the release bearing in the proper direction.
NOTE: Ensure release bearing is properly positioned
during installation, as shown in illustration.
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10. Install driven plate assembly. Use the pilot aligner
5-85253-001-0 (J-24547) to install the driven plate
assembly.
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11. Install pressure plate assembly and tighten the bolts
holding the pressure plate assembly in the order
shown in illustration.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
201RS017
12. Remove the aligner.
NOTE: Do not strike the aligner with a hammer to remove
it.
13. Install transmission assembly.

The chassis electrical system is a 12–volt system with a
negative ground polarity.
Wire size are appropriate to respective circuits, and
classified by color. (The classification of harnesses by
color is shown on the circuit diagram for ease of harness
identification.)
The wire size is determined by load capacity and the
length of wire required.
The vehicle harnesses are: body harness, chassis
harness, engine room harness, instrument harness,
transmission harness, engine ECGI harness, dome light
harness, door harness, rear body harness, tailgate
harness, SRS harness and battery cables.
The harnesses are protected either by tape or corrugated
tube, depending on harness location.
The circuit for each system consists of the power source,
wire, fuse, relay, switch, load parts and ground, all of
which are shown on the circuit diagram.
In this section, each electrical device is classified by
system.
For major parts shown on the circuit based on the circuit
diagram for each system, a summary, diagnosis of
troubles and inspection procedures are detailed.
Notes for Working on Electrical
Items
Disconnecting the Battery Cable
1. All switches should be in the “OFF” position.
2. Disconnect the battery ground cable (2).
3. Disconnect the battery positive cable (1).
CAUTION: It is important that the battery ground
cable be disconnected first. Disconnecting the
battery positive cable first can result in a short circuit.
Connecting the Battery Cable
Follow the disconnecting procedure in the reverse order.CAUTION: Clean the battery terminal and apply a
light coat of grease to prevent terminal corrosion.
Disconnecting the Connector
Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards
you (1).
Other tang locks are released by pressing them forward
(2).
Determine which type of tang lock is on the connector
being handled.
Firmly grasp both sides (male and female) of the
connector (3).
Release the tang lock and carefully pull the two halves of
the connector apart.
Never pull on the wires to separate the connectors (4).
2
1
General Description
1
2
3
4

P C M
C-1 A16
C-3
C-2 F14
C2
C-3
M-7M-7
M-7
M-7 E14
C-2D9
C-3M-6M-6C-2 F7
D2
C-3E3
C-3
M-6
M-6
M-6C-3 E4
E1
C-3
M-15
M-15E2
13
H-53
14
H-53
16
H-53
15
231 4
9 17 15
10
8
11
12
5
3412 21
6
7
5
13 7
1 H-53
COMMON CHAMBER
SPEED
SENSOR
(TRANSMISSION)
ADAPTER CASE
(TRANSMISSION) MAIN CASE
(TRANSMISSION)
1.0
B/R 1.25
B/P 1.25
V/W 1.25
V/R 0.5
BR/L 0.5
R/B
0.5
GR 0.85
GR
0.5
W 0.5
R 1.25
V/W 1.25
V/R 0.75
BR/L 0.75
G 1.25
BR/W 0.5
BR/B 0.5
BR/R 0.5
BR/Y
1.25
BR/W 0.75
BR/B 0.75
BR/R 1.25
BR/Y0.5
G/R0.5
W 0.5
R
JOINT
CONNEC-
TOR
E-29H-5
JOINT
CONNECTORC-88
C-88
(+) (–) (+) (–)H-53
H-53 H-53 H-53 H-53 H-53H-53 H-53
OIL TEMP.
SENSOR
TCC
SOLENOID2-3
SOLENOID 1-2,3-4
SOLENOID BAND APPLY
FORCE
MOTOR
PCM:POWERTRAIN CONTROL MODULE
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P C M
C-1 A16
C-3
C-2 F14
C2
C-3
M-7M-7
M-7
M-7 E14
C-2D9
C-3M-6M-6C-2 F7
D2
C-3E3
C-3
M-6
M-6
M-6C-3 E4
E1
C-3
M-15
M-15E2
13
H-53
14
H-53
16
H-53
15
231 4
9 17 15
10
8
11
12
5
3412 21
6
7
5
13 7
1 H-53
COMMON CHAMBER
SPEED
SENSOR
(TRANSMISSION)
ADAPTER CASE
(TRANSMISSION) MAIN CASE
(TRANSMISSION)
1.0
B/R 1.25
B/P 1.25
V/W 1.25
V/R 0.5
BR/L 0.5
R/B
0.5
GR 0.85
GR
0.5
W 0.5
R 1.25
V/W 1.25
V/R 0.75
BR/L 0.75
G 1.25
BR/W 0.5
BR/B 0.5
BR/R 0.5
BR/Y
1.25
BR/W 0.75
BR/B 0.75
BR/R 1.25
BR/Y0.5
G/R0.5
W 0.5
R
JOINT
CONNEC-
TOR
E-29H-5
JOINT
CONNECTORC-88
C-88
(+) (–) (+) (–)H-53
H-53 H-53 H-53 H-53 H-53H-53 H-53
OIL TEMP.
SENSOR
TCC
SOLENOID2-3
SOLENOID 1-2,3-4
SOLENOID BAND APPLY
FORCE
MOTOR
PCM:POWERTRAIN CONTROL MODULE
D08RW597

3
X-15X-15
4
3.0
B/Y
0.85
R/B
0.75
R/B0.5
R/BC-3 10A
TURN,BACKSTARTER SW
(IG1)
C-4 10A
ELEC.IGN.
BACK UP
LIGHT
SW
0.75
R/L0.75
GR 1
M-86H-11H-717
0.85
L/W
0.75
L/W0.5
L/W
0.5
L/W
TRANSMISSION
SW-1, 21
M-116H-10H-127
D
E
B BACK UP
LIGHT0.75
R/L
0.5
R/L
0.5
R/L 0.5
R/L
0.5
R/L0.75
GR
0.5
GR
0.5
GR 6H-42H-117
8
H-42H-1015
D
0.5
GR
E
0.5
L/W
1
M-9
1
M-2
D08RW827