1998 OPEL FRONTERA direction

MANUAL TRANSMISSION7B–13
(4JX1)
225RW020
5. Apply a force of about 113N (26 Ib) to the tip of the
shift fork in the direction of the transmission to engage
the clutch pressure plate and release bearing.
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage each
other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine while applying a
force of about 25 N (5.5 lb). If the shift fork will not move,
then they are securely engaged.
220RS006
6. Install three flywheel under cover (6VE1).

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

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

MANUAL TRANSMISSION7B–47
11. Install the clutch hub No.1.
1. Install the 3 inserts and 3 insert springs to the
clutch hub No.1.
Reference: While pushing the insert spring
with a screwdriver, install the inserts.
226RW108
2. Install the clutch hub No.1 to the reverse gear.
NOTE: Check the clutch hub No.1 installing direction, as
shown.
226RW109
3. Using installer 5–8840–2554–0 (J–42798) and a
press, install the hub No.1 by retaining the
reverse gear.NOTE:
Align the projection of inner ring with hub No.1 slots.
Check that the gear rotates smoothly.
226RW205
4. Select a snap ring that will allow minimum axial
play.
Mark
Thickness
A2.30–2.35mm (0.091–0.093in)
B2.35–2.40mm (0.093–0.095in)
C2.40–2.45mm (0.095–0.097in)
D2.45–2.50mm (0.097–0.098in)
E2.50–2.55mm (0.098–0.100in)
F2.55–2.60mm (0.100–0.102in)
G2.60–2.65mm (0.102–0.104in)
226RW111

7B–60MANUAL TRANSMISSION
2. Install the synchronizer outer ring, synchronizer
cone ring, and synchronizer pull ring to the
reverse block ring.
226RW121
3. Turn to 30 degree the reverse synchronizer pull
ring.
226RW080
4. Install the hub sleeve No.3 and reverse block ring
set to the counter 5th gear.
NOTE: Check the hub sleeve No.3 direction, as shown.
Reference: While pushing the 3 inserts,
install the synchronizer ring assembly to the
hub sleeve No.3.
226RW184
5. Slide the hub sleeve No.3.
226RW123

CLUTCH7C–11
1. Use a straight edge and a feeler gauge to measure
the pressure plate friction surface flatness in four
directions.
2. If any of the measured values exceeds the specified
limit, the pressure plate must be replaced.
Pressure Plate Warpage
Limit: 0.3 mm (0.012 in)
Clutch Cover
201RS004
1. Visually check the entire clutch cover for excessive
wear, cracking, and other damage.
2. The clutch cover must be replaced if any of these
conditions are present.
Clutch Set Force
201RS005
1. Invert the pressure plate assembly.2. Place a new driven plate over the pressure plate. A
metal sheet with “A” thickness of 8.3 mm (0.327 in)
may be used in place of the driven plate.
3. Compress the pressure plate assembly until the
distance “B” becomes 12 mm (0.472 in).
4. Note the pressure gauge reading.
5. If the measured value is less than the specified limit,
the pressure plate assembly must be replaced.
Clutch Set Force
Standard: 7208 N ( 1621 lb)
Limit: 6468 N (1454 lb)
Diaphragm Spring Finger Height
201RW009
Legend
(1) Release Side
1. Place a new driven plate or a 8.3 mm (0.327 in)
spacer beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm
spring.
3. There are two ways to do this.
4. Use a bench press to press down on the assembly
from the top.
5. Tighten the fixing bolts.
NOTE: Preload on diaphragm spring finger must be 49 –
98 N (11 – 22 lb) in direction of release, when clutch cover
assembly is bolted to the flywheel.
6. Measure the spring height from base to spring tip “A”.
If the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Diaphragm Spring Finger Height
Standard: 49.9 mm – 51.9 mm (1.965 in –
2.043 in)

7C–16CLUTCH
8. Apply molybdenum disulfide type grease to the areas
shown in illustration.
201RW012
9. Install the release bearing in the proper direction.
NOTE: Ensure release bearing is properly positioned
during installation, as shown in illustration.
201RW020
10. Install driven plate assembly. Use the pilot aligner
5-85253-001-0 (J-24547) to install the driven plate
assembly.
201RW027
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.

LIGHTING SYSTEM8A–11
Side Turn Signal Light Bulb
Removal
1. Disconnect the battery ground cable.
2. Pull the light/bulb(1) toward you while pushing the
light housing in the rear direction of the vehicle to
release its lock.
3. Remove the bulb by turning it counterclockwise while
pushing it at the same time.
801RW013
Installation
To install, follow the removal steps in the reverse order.
Rear Turn Signal Light Bulb
Removal
1. Disconnect the battery ground cable.
2. Remove the three screws and release the lock at two
positions.
3. Remove the rear combination light(3).
4. Remove the turn signal light socket/bulb(1) by turning
it counterclockwise.
5. Remove the bulb(2) by turning it counterclockwise
while pushing it at the same time.
803RS002
Installation
To install, follow the removal steps in the reverse order.