Opel Frontera UBS. Service manual — part 2632
7B–4
MANUAL TRANSMISSION
Diagnosis
Condition
Possible cause
Correction
Abnormal noise
Flywheel pilot bearing worn
Replace
Bearings worn or broken (Mainshaft,
counter shaft, and transfer shaft)
Replace
Gear tooth contact surfaces worn or
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)
Replace
Splines worn (Mainshaft,
synchronizer clutch hub)
Replace
Gear or bearing thrust face seized
Replace
Lack of backlash between meshing
gears
Replace
Hard Shifting
Improper clutch pedal free play
Readjust
Change lever sliding portions worn
Repair or replace
Regrease
Shift block, shift rod and/or control
box sliding faces worn
Replace
Shift arm and synchronizer sleeve
groove worn
Replace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)
Replace worn parts
Synchronizer parts worn
Replace
Walking or Jumping out of gear
Detent ball worn
Replace
Detent spring weakened or broken
Replace
Shift rod and/or control box sliding
faces worn
Replace
Shift arm and synchronizer sleeve
groove worn
Replace worn parts
Thrust washer, collar, and/or gear
thrust faces worn (Mainshaft and
counter shaft thrust play)
Replace worn parts
Bearings worn or broken
Replace
Splines worn (Mainshaft,
synchronizer hub)
Replace
Synchronizer spring weakened or
broken
Replace
Oil leakage
Loose drain plug(s) and/or filler
plug(s)
Tighten
Replenish oil
Defective or improperly installed
gasket(s)
Replace
Oil seal worn or scratched
Replace
MANUAL TRANSMISSION
7B–5
Manual Transmission Assembly
Transmission and Associated Parts
220RW108
Legend
(1) Gear Control Lever and Knob
(2) Transfer Control Lever and Knob
(3) Front Console Assembly
(4) Grommet Assembly
(5) Transfer Protector
(6) Rear Propeller Shaft
(7) Front Propeller Shaft
(8) Exhaust Pipe
(9) Backup Lamp, 4WD Indicator, and 1–2
Indicator Switch Harness Connector
(10) Speedometer Sensor and 2WD–4WD Actuator
Harness Connector
(11) Slave Cylinder Heat Protector
(12) Harness Heat Protector
(13) Slave Cylinder
(14) Dust Cover
(15) Engine Rear Mount Nut
(16) Engine Rear Mount Bolt
(17) Engine Rear Mount
(18) Third Crossmember
(19) Flywheel Under Cover
(20) Transmission Retaining Bolt
(21) Transmission Assembly with Transfer Case
7B–6
MANUAL TRANSMISSION
Removal
NOTE: Before remove the transmission and transfer
assembly from the vehicle, change the transfer mode to
2WD using push button on dash panel.
1. Remove engine hood.
2. Disconnect battery ground cable.
3. Remove the gear control lever knob.
4. Remove the front console assembly.
5. Remove the grommet assembly.
6. Remove the transmission control lever and transfer
control lever.
235RW014
7. Raise and support the vehicle with suitable jack
stand.
8. Remove transfer protector.
9. Remove the rear propeller shaft.
NOTE: Apply alignment marks on the flange at the both
front and rear side.
(4JX1)
401RW060
10. Remove the front propeller shaft.
NOTE: Apply alignment marks on the flange at both the
front and rear sides.
401RS003
11. Disconnect two oxygen sensor connectors from the
transmission harness (6VE1).
12. Remove the front and 3 way exhaust pipe (6VE1).
Remove the exhaust pipe with catalytic converter
(4JX1).
(4JX1)
150RW041
MANUAL TRANSMISSION
7B–7
13. Disconnect the backup lamp switch, 4WD indicator
switch and 1–2 indicator switch harness connectors.
826RW023
14. Disconnect the speedometer sensor and 2WD-4WD
actuator harness connectors.
826RW024
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