1998 OPEL FRONTERA lock

7B–18MANUAL TRANSMISSION
Transmission (AR-5)
Disassembled View
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Legend
(1) Snap Ring
(2) Bearing
(3) Top Gear Shaft
(4) Block Ring
(5) Roller Bearing
(6) Snap Ring
(7) Clutch Hub No.2 Assembly
(8) 3rd Block Ring
(9) 3rd Gear
(10) 3rd Gear Needle Roller Bearing
(11) Mainshaft
(12) Thrust Washer Pin
(13) 2nd Gear Needle Roller Bearing
(14) 2nd Gear
(15) Synchronizer Assembly(16) Clutch Hub No.1 Assembly
(17) Snap Ring
(18) Synchronizer Assembly
(19) 1st Gear
(20) 1st Gear Bearing Spacer
(21) 1st Gear Needle Roller Bearing
(22) 1st Gear Thrust Washer
(23) Mainshaft Bearing
(24) Snap Ring
(25) 5th Gear
(26) Snap Ring
(27) Intermediate Plate
(28) Bearing Retainer
(29) Snap Ring
(30) Front Bearing Assembly
(31) Counter Gear Shaft

MANUAL TRANSMISSION7B–19
(32) Thrust Washer Pin
(33) Reverse Idle Gear
(34) Reverse Idle Gear Shaft
(35) Counter Gear Shaft Center Bearing
(36) Snap Ring
(37) Thrust Washer
(38) Roller Bearing(39) Counter 5th Gear
(40) Reverse Block Ring
(41) Synchronizer Assembly
(42) Hub Sleeve No.3
(43) 5th Gear Spline Piece
(44) Snap Ring
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Legend
(1) 3rd-4th Shift Arm
(2) 1st-2nd Shift Arm
(3) 3rd-4th Shift Rod
(4) Ball
(5) Spring
(6) 1st-2nd Shift Rod
(7) Snap Ring
(8) Interlock Pin(9) Reverse Shift Arm Bracket
(10) E–Ring
(11) Reverse Shift Arm No.2
(12) Reverse Shift Arm No.1
(13) 5th Reverse Shift Rod
(14) Spring Pin
(15) 5th Shift Arm
(16) Reverse Shift Rod

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–30MANUAL TRANSMISSION
20. Remove the top gear shaft.
1. Remove the top gear shaft from mainshaft.
NOTE: Don’t fall needle roller bearing.
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2. Remove the 4th block ring and roller bearing.
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21. Disassemble the top gear shaft assembly.
1. Check for wear or damage.
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2. Remove the front bearing shaft snap ring.
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7B–34MANUAL TRANSMISSION
8. Remove the reverse gear from clutch hub No.1.
9. Remove the 3 inserts and 3 compression springs.
When removing the inserts, push the insert
spring with a screwdriver.
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10. Remove the snap ring.
NOTE: Don’t damage the bearing surface.
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11. Using a press, remove following parts.
1. Clutch hub No.2 assembly (1).
2. 3rd block ring (2).
3. 3rd gear (3).
4. 3rd gear needle roller bearing (4).
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12. Using screwdriver, remove the 2 insert springs,
hub sleeve No.2, clutch hub No.2 and 3 inserts.
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MANUAL TRANSMISSION7B–35
24. Remove the shift parts and interlock parts.
1. Mount the intermediate plate through the
aluminum plate in a vise.
2. Using a plastic hammer, tap the 5th shift rod on
the neutral.
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3. Using a torx socket wrench(T40), remove the 4
plugs.
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4. Using a magnetic finger, remove 3 springs and
balls.
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5. Using 2 screwdrivers and a hammer, remove 2
snap rings from each shift fork rod.
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7B–36MANUAL TRANSMISSION
6. Pull out the 3rd–4th shift rod at the rear.
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7. Using a magnetic finger, remove the interlock pin
and straight pin.
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8. Pull out the 1st–2nd shift rod at the rear.
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9. Using a magnetic finger, remove the interlock pin.
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MANUAL TRANSMISSION7B–37
10. Using 2 screwdrivers and a hammer, remove 2
snap rings.
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11. Pull out the 5th-reverse shift rod at the front.
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12. Using a magnetic finger, remove the interlock pin
from the intermediate plate. Remove the ball
from the reverse shift arm No.1.
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13. Pull out at the rear reverse shift rod, reverse shift
arm No.1 and reverse shift arm No.2 at the same
time.
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