Shift forks and rods (Opel Frontera B)

Removal

Remove the gearbox housing from the intermediate plate (see the relevant chapter).

Remove 2 bolts and remove the retainer plate, gasket, and three springs from the intermediate plate.

Use a magnetic tool to remove the 3 balls from the slots in the spacer plate.



Remove the retaining spring from the 5th/Reverse shift fork.



Using a cylindrical punch, knock out the 3 cylindrical pins that secure the gear shift forks to the rods.

Warning: To prevent damage to the piston rods, place wooden blocks between the piston rod and the gears.

Remove the 5th/reverse gear shift fork rod, the holding spring fork, the springs, the 1st/2nd gear shift fork rod, the 3rd/4th gear shift fork rod, and the 1st/2nd gear shift fork in sequence.

Be careful to preserve the locking pins located in the intermediate plate between the shift rods.

Examination

Check all removed parts for wear and damage.

Before installation, lubricate all parts with transmission oil.

Use a micrometer to measure the thickness of the shift fork tabs.



Thickness of paws:

• 1st/2nd gear shift fork: 9.00-9.85 mm
• 3rd/4th gear shift fork: 9.00-9.80 mm
• 5th gear/reverse gear shift fork: 9.00-9.80 mm

If the thickness of the shift fork tabs is below the specified limit, replace the shift fork.



In a free state, use a caliper to measure the length of the gearshift rod retainer springs.



Length of springs in free state of gear shift rod retainers: 26.20-26.80 mm

Measure the force required to compress the spring to a length of 20 mm.



The force that must be applied to compress the spring to a length of 20 mm: 8.9-9.0 kg

Installation

Install the 1st/2nd gear and 3rd/4th gear shift forks onto the synchronizer bushings.





Insert the 3rd/4th gear shift fork rod through the middle hole in the intermediate plate, then pass it through the 2 shift forks.



Insert the locking pins into the intermediate plate on both sides of the shift fork shaft.

Install the 1st/2nd shift fork rod into the intermediate plate, then pass it through the hole in the fork.



Install the 5th/Reverse shift fork and retaining spring, then insert the shift rod.





Use new pins to secure the forks to the shift rods.

Original article on the web portal: www.OPELBOOK.ru

Warning: To prevent damage to the piston rods, place wooden blocks between the piston rod and the gears.

Secure the 5th/Reverse shift fork retaining spring.

Install the balls and springs into the intermediate plate.

Install the retainer plate with a new gasket and secure with bolts, tightening them to a torque of 20 Nm.



Install the gearbox housing onto the intermediate plate (see the relevant chapter).