1998 OPEL FRONTERA lock

7B–40MANUAL TRANSMISSION
3. Reverse block ring set.
1. Using a thickness gauge, measure the clearance
between the counter 5th gear spline piece and
reverse block ring.
Standard: 0.7 – 1.7 mm (0.028 – 0.067 in)
226RW084
4. Reverse idle gear and reverse idle gear shaft.
1. Mount the reverse idle gear and reverse idle gear
shaft in a vise.
2. Using a dial indicator, measure the reverse idle
gear radial clearance.
Standard: 0.040–0.082mm (0.0016–0.0032in)
226RW083
3. If the clearance exceeds the maximum, measure
the gear inside diameter and shaft diameter.
Standard
Shaft Diameter: 23.979 – 24.000 mm
(0.94405 – 0.94488 in)
Gear Diameter: 24.040 – 24.061 mm
(0.94645 – 0.94728 in)
226RW082
5. Reverse shift arm No.2 thrust clearance.
1. Using a thickness gauge, measure the clearance
between the reverse idle gear and shift arm No.2.
Standard: 0.05 – 0.35 mm (0.002 – 0.014 in)
226RW081

MANUAL TRANSMISSION7B–41
Reassembly
1. Install the top gear shaft assembly.
1. Using installer 5–8840–2559–0 (J–42904) and a
press, install a new bearing.
NOTE: Outer race snap ring groove (1) toward front.
226RW196
2. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A2.10 – 2.15 mm (0.083 – 0.085 in)
B2.15 – 2.20 mm (0.085 – 0.087 in)
C2.20 – 2.25 mm (0.087 – 0.089 in)
D2.25 – 2.30 mm (0.089 – 0.091 in)
E2.30 – 2.35 mm (0.091 – 0.093 in)
F2.35 – 2.40 mm (0.093 – 0.095 in)
G2.40 – 2.45 mm (0.095 – 0.097 in)
226RW061
3. Using a snap ring expander, install the new snap
ring.
226RW062
4. Install the 4th block ring.
226RW063

7B–42MANUAL TRANSMISSION
5. Using a thickness gauge, measure the clearance
between the 4th block ring back and gear spline
end.
Standard: 0.75 – 1.65 mm (0.030 – 0.065 in)
226RW064
6. Check the braking effect of the block ring. Turn
the block ring in one direction while pushing it to
the gear cone. Check that the ring locks. If it does
not lock, replace the block ring.
226RW060
7. Install the needle roller bearing.
2. Reassemble the mainshaft assembly.
NOTE: Apply all parts with engine oil before installing
them.3. Inspect block ring
1. Using a thickness gauge, measure the clearance
between the synchronizer ring back and gear
spline end.
Gear
Standard Clearanse
1st0.80–1.60mm (0.032–0.063in)
2nd0.65–1.75mm (0.026–0.069in)
3rd0.75–1.65mm (0.030–0.065in)
226RW105
2. Turn the synchronizer ring in one direction while
pushing it to the gear cone. Check that the ring
locks.
226RW106

7B–44MANUAL TRANSMISSION
226RW096
7. Inspect mainshaft.
1. Using a micrometer, measure the outer diameter
of the mainshaft journal.
Measure
Position
Standard
A37.984 – 38.000 mm (1.4954 – 1.4961 in)
B46.984 – 47.000 mm (1.8498 – 1.8504 in)
C38.979 – 38.995 mm (1.5346 – 1.5352 in)
226RW078
2. Using a micrometer, measure the mainshaft
flange thickness.
Standard: 5.0 mm (0.197 in)
226RW079
3. Install the mainshaft to V-blocks.
4. Use a dial indicator to measure the mainshaft
central portion run-out.
Standard: less than 0.015 mm (0.0006 in)
226RW097

MANUAL TRANSMISSION7B–45
8. Install 3rd gear.
1. Install the 3rd gear needle bearing, 3rd gear and
3rd block ring to the mainshaft.
226RW098
9. Install the clutch hub No.2.
1. Install the clutch hub No.2 and hub sleeve No.2.
NOTE: Be careful the direction of the clutch hub No.2, as
shown.
2. Using a screwdriver, install 3 inserts and 2
springs.
NOTE: Position the insert springs so that their end gaps
are not in line.
226RW099
3. Using installer 5–8840–2553–0 (J–42797) and a
press, install the clutch nob No.2 and hub sleeve
No.2 to the mainshaft.NOTE:
Align the brock ring slots with the inserts.
Check that the gear rotates smoothly.
226RW206
4. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A1.80–1.85mm (0.071–0.073in)
B1.85–1.90mm (0.073–0.075in)
C1.90–1.95mm (0.075–0.077in)
D1.95–2.00mm (0.077–0.079in)
E2.00–2.05mm (0.079–0.081in)
F2.05–2.10mm (0.081–0.083in)
G2.10–2.15mm (0.083–0.085in)
226RW102

7B–46MANUAL TRANSMISSION
5. Using a snap ring expander, install the new snap
ring.
NOTE: Be careful not to damage the bearing surface.
226RW101
6. Using a thickness gauge, inspect the 3rd gear
thrust clearance.
Standard: 0.10 – 0.25mm (0.004 – 0.010 in)
226RW103
10. Install the 2nd gear.
1. Install the synchronizer ring set No.1 to the 2nd
gear.
NOTE: Align the nail of middle ring with gear spline slots.
226RW104
2. Install the needle roller bearing, 2nd gear and 2nd
gear block ring set to the mainshaft.
226RW107

7B–54MANUAL TRANSMISSION
2. Install the reverse shift rod from the rear side by
pushing the ball on using a screwdriver.
226RW126
21. Install the reverse-5th shift rod.
1. Install the reverse shift arm No.1 lock ball to the
reverse shift arm No.1.
2. Install the interlock pin to the intermediate plate.
226RW039
3. Put in the reverse-5th shift rod from the front.
226RW011
4. Using a screwdriver and a hammer, install the 2
new shift rod snap rings to the 5th-reverse shift
rod and reverse shift rod.
226RW037

MANUAL TRANSMISSION7B–55
22. Install 1st–2nd shift rod.
1. Install the interlock pin to the intermediate plate.
226RW042
2. Put in the 1st–2nd shift rod from the rear.
226RW044
23. Install 3rd–4th shift rod.
1. Install the straight pin and interlock pin to the
intermediate plate.
226RW043
2. Put in the 3rd–4th shift rod from the rear.
226RW046