Opel Frontera UBS. Service manual — part 627
7C–22
CLUTCH
Master Cylinder
Disassembled View
208RW016
Legend
(1) Master Cylinder Assembly
(2) Gasket
(3) Damper Cylinder Assembly
(4) Nut
(5) Push Rod Damper
CLUTCH
7C–23
Disassembly
(4JX1)
1. Remove damper cylinder assembly and gasket.
2. Remove push rod damper.
NOTE: The master cylinder assembly cannot be
disassembled because of point–staked rod stopper.
Inspection and Repair
Clean and inspect the removed parts.
Make necessary parts replacement if any abnormalities
such as wear, oil leaks or other damage are found through
inspection.
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1. Push rod set length
RHD: 117.5 mm (4.626 in)
LHD: 119 mm (4.685 in)
2. Push rod nut torque
17 N·m (1.7 kg·m/12 Ib ft)
3. Damper cylinder torque
47 N·m (4.8 kg·m/35 Ib ft)
7C–24
CLUTCH
Slave Cylinder
Disassembled View
206RW004
Legend
(1) Cylinder Body
(2) Spring
(3) Piston and Piston Cup
(4) Boot
(5) Push Rod
Disassembly
1. Remove boot.
2. Remove push rod.
3. Remove piston and piston cup.
4. Remove spring.
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Cylinder Body
206RS003
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it
if necessary.
CLUTCH
7C–25
Piston and Piston Cup
1. Visually inspect the disassembled piston and piston
cup for excessive wear and damage.
2. Replace the inner parts with new parts shown in the
illustration.
206RS004
3. Measure the clearance between slave cylinder wall
and piston.
4. If the measured value exceeds the specified limit, the
slave cylinder assembly must be replaced.
Standard: 0.07 mm (0.0028 in)
Limit: 0.15 mm (0.0059 in)
206RS005
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1. Before installing the parts, apply a thin coat of rubber
grease.
2. Install cup in groove in piston with the lip turned to the
front of cylinder. Use care so as not to scratch the
cylinder.
206RS006
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