1998 OPEL FRONTERA lock

TRANSFER CASE (STANDARD TYPE)
4D1–31
Disassembly
1. Use a pair of snap ring pliers to remove the snap ring
(42).
2. Use a bearing remover 5–8840–2155–0 ( J–37217)
and puller 5–8840–2027–0 (J–37487) to remove the
ball bearing (41).
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3. Install the front companion flange temporarily.
4. Use the Companion flange holder 5–8840–0133–0
(J–8614–11) and lock nut wrench 5–8840–2156–0
(J–37219) to remove the lock nut (40).
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5. Remove the front companion flange.
6. Remove the snap ring (33) from the transfer case (1).
7. Remove the input shaft assembly (30) from the
transfer case.
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8. Use a universal puller to remove the high–low clutch
hub and sleeve (39), and transfer input gear (38).
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9. Remove needle bearing (37).

4D1–32
TRANSFER CASE (STANDARD TYPE)
10. Remove the bearing collar (36).
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11. Remove the ball (35).
12. Remove the plate (34).
13. Use a bench press and the ball bearing remover
5–8840–0015–0 (J–22912–01) to remove the ball
bearing (32) from input shaft (31).
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14. Remove the bearing snap ring (2) from the transfer
case, using a pair of snap ring pliers.15. Use a plastic hammer to tap the front output gear
assembly (3) free.
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16. Remove the bearing snap ring (19). Remove the ball
bearing (18) and bearing collar (17) together with
front output gear assembly: including following parts.
17. Use a bench press and the bearing remover
5–8840–0015–0 (J–22912–01) to remove the
following parts.
18. Remove the sub–gear snap ring (16), spacer (15),
belleville spring (14), and sub–gear (anti–lash plate)
(13).(M/T)
19. Remove the front output gear (11) and needle bearing
(12).
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20. Remove the inside ring (10). (Shift On The Fly model)
2 1 . R e m o v e t h e o u t s i d e r i n g ( 9 ) . ( S h i f t O n T h e F l y m o d e l )
22. Remove the block ring (8). (Shift On The Fly model)
23. Use a bench press and bearing remover
5–8840–0015–0 (J–22912–01) to remove the
2WD–4WD clutch hub and sleeve assembly (7) and
stopper plate (6). (Shift On The Fly model)

4D1–34
TRANSFER CASE (STANDARD TYPE)
2. If the measured value exceeds the specified limit, the
gear must be replaced.
Gear inside diameter
Standard : 48.000–48.013 mm (1.8898–1.8903 in)
Limit : 48.10 mm (1.894 in)
226RS040
Clutch Hub Spline Play
1. Set a dial indicator to the clutch hub to measured.
2. Move the clutch hub as far as possible to both the right
and the left.
Note the dial indicator reading.
3. If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Clutch hub spline play
Standard : 0–0.1 mm (0–0.004 in)
Limit : 0.2 mm (0.008 in)
226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)
226RS043
Synchronizers
The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
Teeth for wear, scuffs, nicks, burrs or breaks.
Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace the
component.
Block Ring and Insert Clearance
1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limit, the
block ring and the insert must be replaced.
Block ring and insert clearance
Standard : 2.46–2.74 mm (0.097–0.108 in)

TRANSFER CASE (STANDARD TYPE)
4D1–35
Limit : 3.0 mm (0.118 in)
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2WD–4WD 3–Cone Synchronizer (Shift On
The Fly model)
1. Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit, the
2WD–4WD synchronizer assembly must be
replaced.
Block ring and insert clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 mm (0.031 in)
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Clutch Hub and Insert Clearance
1. Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
2. If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard : 0.01–0.19 mm (0.0004–0.0075 in)
Limit : 0.3 mm (0.012 in)
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Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.

4D1–36
TRANSFER CASE (STANDARD TYPE)
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard : 23.4 mm (0.921 in)
Limit : 22.8 mm (0.898 in)
Interlock pin
Standard : 1.59 mm (0.063 in)
Limit : 1.53 mm (0.060 in)
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Detent Spring Tension
1. Use a spring tester to measure the detent spring
tension.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Compressed height : 18.7 mm (0.736 in)
Standard : 68.6–88.2 N (7.0–9.0kg/15.4–19.8 lb)
Interlock pin
Compressed height : 11.5 mm (0.453 in)
Standard : 9.8 N (1.0kg/2.2 lb)
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Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
2. If the measured value is less than the specified limit,
the shift arm must be replaced.
Shift arm thickness
Standard : 9.60–9.85 mm (0.378–0.388 in)
Limit : 9.0 mm (0.354 in)
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TRANSFER CASE (STANDARD TYPE)
4D1–39
14. Assemble the 2WD–4WD clutch hub and sleeve
assembly (7).
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15. Engage the springs in the same insert with the open
ends away from each other. (Shift On The Fly model)
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16. Place the snap ring (2), a new stopper plate (6) (Shift
On The Fly model) and the clutch sleeve and hub
assembly (7) on the front output shaft (5).
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Legend
(6) Front Output Gear
17. The clutch hub face (with the heavy boss) must be
facing the front output gear side.
18. Use a bench press to slowly force the clutch hub and
sleeve assembly (7) together with the stopper plate
(6) (Shift On The Fly model) into place.
19. Align the inserts with the block ring insert grooves.
Install the block ring (8) (Shift On The Fly model) to
the clutch sleeve and hub assembly (7).
20. Install the outside ring (9) (Shift On The Fly model),
inside ring (10) (Shift On The Fly model) and needle
bearing (12) to the front output gear (11) and bearing
collar (17).
NOTE: Coat all parts with transmission oil before
installing them.
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4D1–40
TRANSFER CASE (STANDARD TYPE)
21. Apply engine oil to the thrust surfaces of the sub–gear
(13), the belleville spring (14), and the spacer (15).
(M/T)
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22. Install the sub–gear (anti–lash plate) (13), belleville
spring (14), and spacer (15) to the front output gear
(11).(M/T)
23. Install the sub–gear snap ring (16). (M/T)
24. Use a bench press to install the needle bearing collar
(17) together with the front output gear, aligning inside
ring claw with block ring groove.
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25. Install ball bearing (18), using a bench press.26. Select a snap ring that will allow the minimum axial
play.
Clearance : 0–0.1 mm (0–0.004 in)
Snap ring availability:
Snap ring thicknessColor coding
1.55 mm (0.061 in)White
1.60 mm (0.063 in)Ye l l o w
1.65 mm (0.065 in)Blue
1.70 mm (0.067 in)Pink
1.75 mm (0.069 in)Green
1.80 mm (0.071 in)Brown
1.85 mm (0.073 in)Red
1.90 mm (0.075 in)Orange
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226RS021

TRANSFER CASE (STANDARD TYPE)
4D1–41
27. Use a pair of snap ring pliers to install the snap ring
(19) to the output shaft (5).
Sub gear (anti lash plate) preload (M/T)
1. Hook a length of piano wire (4) over one of the
sub–gear (5) teeth.
2. Attach the other end of the piano wire to (4) a
spring balancer.
3. Measure the sub–gear preload.
Preload: 59–98 N (6.0–10.0kg/13–22 lb)
(M/T)
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28. Install front output gear assembly (3) to the transfer
case (1).
29. Use a pair of snap ring pliers to install the snap ring (2)
to the transfer case (1).
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
30. Use a bench press to install the ball bearing (32) to the
input shaft (31).
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31. Install the plate (34), ball (35), and bearing collar (36)
and place the snap ring (33).
32. Install the needle bearing (37) and input gear (38).
33. The clutch hub face (with the heavy boss) must be
facing the transfer input gear side (7).
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34. Install the high–low clutch hub and sleeve (39), using
a bench press.
35. Install the input shaft assembly (30) to the transfer
case (1).
36. Install the snap ring (33) to the transfer case (1).
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
37. Install the front companion flange temporarily and use
the flange holder 5–8840–0133–0 (J–8614–11) and
lock nut wrench 5–8840–2156–0 (J–37219) to install
the lock nut (40).
Torque: 137 Nꞏm (14.0kgꞏm/101 lb ft)
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38. Use the punch to stake the lock nut (40) at one spot.