Opel Frontera UBS. Service manual — part 574
MANUAL TRANSMISSION
7B–1
TRANSMISSION
MANUAL TRANSMISSION
CONTENTS
Service Precaution
7B–1
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General Description
7B–2
. . . . . . . . . . . . . . . . . . . . .
Diagnosis
7B–4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission Assembly
7B–5
. . . . . . . . . . .
Transmission and Associated Parts
7B–5
. . . . . .
Removal
7B–6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7B–11
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal (Transfer Adapter)
7B–17
. . . . . . . . . .
Removal
7B–17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7B–17
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (AR-5)
7B–18
. . . . . . . . . . . . . . . . . . . . .
Disassembled View
7B–18
. . . . . . . . . . . . . . . . . . . .
Disassembly
7B–21
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection
7B–39
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Reassembly
7B–41
. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications
7B–68
. . . . . . . . . . . . .
General Specifications
7B–68
. . . . . . . . . . . . . . . . .
Torque Specifications
7B–69
. . . . . . . . . . . . . . . . . .
Special Tools
7B–72
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Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
7B–2
MANUAL TRANSMISSION
General Description
(6VE1)
A07RW044
MANUAL TRANSMISSION
7B–3
(4JX1)
A07RW043
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
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