1998 OPEL FRONTERA oil

4D2–28
TRANSFER CASE (TOD)
Tension of Lock-up Fork Spring
If the measurement exceeds the limit, replace the
spring. (When compressed to 41.4 mm)
Standard : 27.1-33.8 N {2.76-3.45 kg/6.08-7.61 Ib}
Allowable limit : 24.5 N {2.5 kg/5.5 Ib}
014RW048
Tension of Detent Spring Assembly
If the measurement exceeds the limit, replace the
spring. N {kg} (When compressed by 3 mm from the
free length)
Standard : 139 N -203 {14.2-20.7 kg/31.3-45.6 Ib}
Allowable limit : 130 N {13.3 kg/29.3 Ib}
261RW041
Oil Pump
Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is
excessively worn or damaged, replace the pump.
Multi Plate Disk Clutch
If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the part or parts.
266RW003
Coil Assembly
Check the resistance of the coil with a tester. If
defects are observed, replace the assembly.
* (ordinary temperature)
Standard : 1.4
2.0
Allowable limit : 1.05.0
261RW031

4D2–29 TRANSFER CASE (TOD)
Cam Pulley, Cam Ball, and Cam&Coil
Housing
Check the cam balls and cam for excessive wear or
damage. If defective, replace the parts. 4H and 4L
switches.
266RW016
The Parts 4H and 4L Switch
Check the continuity of 4H and 4L switch.
261RW003
261RW049
Switch
Stroke4H Switch
Signal4L Switch
SignalThe
correspo
nding
p
ositionB to Switch
BodyA to Cosition
of
transfer
lever
1OpenOpenHigh
2OpenClose4L
3CloseCloseNeutral

4D2–30
TRANSFER CASE (TOD)
Transfer Case
Disassembled View
265RW015
Legend
(1) Transfer Case
(2) Ball Bearing
(3) Ring Gear
(4) Snap Ring
(5) Input Shaft and Carrier Assembly
(6) Snap Ring(7) Ball Bearing
(8) Snap Ring
(9) Thrust Plate
(10) Carrier Assembly
(11) Snap Ring
(12) Circular Hub
(13) Input Shaft
Reassembly
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the circumference of the new oil
seal and fill the lip with grease (Besco L2 or
equivalent).

4D2–31 TRANSFER CASE (TOD)
3. Using the front output shaft oil seal installer
5-8840-2410-0 (J-42807), install the oil seal to the
transfer case.
261RW053
Front Output Shaft Oil Seal
Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
Distance : 0.93 — 1.43mm (0.037 — 0.056 in)
A04RW003
4. Using the input shaft (main) oil seal installer
5-8840-2411-0 (J-42808), install the oil seal to the
transfer case.
261RW055
Input Shaft Oil Seal
Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
Distance : 3.25 — 3.75mm (0.13 — 0.15 in)
A04RW002

4D2–37 TRANSFER CASE (TOD)
Sprocket and Mechanical Lock
Disassembled View
266RW008
Legend
(1) Strainer
(2) Hose
(3) Oil Pump Assembly
(4) Thrust Washer
(5) Mechanical Lock Hub
(6) Lock-up Sleeve(7) Lock-up Fork
(8) Chain
(9) Lower Drive Sprocket
(10) Front Tone Wheel
(11) Drive Sprocket
(12) Sprocket Spacer
Reassembly
1. Connect the hose and strainer to the oil pump
assembly.
2. Install the oil pump assembly to the output shaft and
set the magnet to the strainer position.
3. Install the thrust washer.
4. Install the spring to the lock-up fork.

4D2–39 TRANSFER CASE (TOD)
Clutch Pack and Clutch Cam
Disassembled View
266RW006
Legend
(1) Clutch Pack Assembly
(2) Insulator Washer
(3) Armature Plate
(4) Snap Ring(5) Wave Spring
(6) Cam Pulley
(7) Cam Ball
(8) Cam and Coil Housing
(9) Thrust Bearing
Reassembly
1. Mount the clutch pack assembly to which the multi
plate disk clutch is already installed to the output
shaft.
NOTE: Mount the clutch pack assembly while adjusting
the phase of both the clutch housing and drive sprocket.
2. Install the insulator washer.
3. Install the armature plate.

4D2–40
TRANSFER CASE (TOD)
4. Using snap ring pliers, install the snap ring.
266RW009
5. Install the wave spring.
6. Install the cam pulley.
7. Place a ball on each groove of the cam pulley.
266RW013
8. Install the cam and coil housing.
9. Install the thrust bearing.

4D2–41 TRANSFER CASE (TOD)
Main Data and Specifications
Leading Particulars
Ty p eTransfer case with low range reduction mechanism
2H Rear wheel drive
TOD Electronically controlled torque split four wheel drive
4L Low-speed mechanical lock-up four wheel drive
Control systemFloor direct control
Gear ratioH1.000
L2.480
Oil quantity, Lit1.9
OilAT F D E X R O N-IIE or ATF DEXRON-III
Torque Specifications
E04RW012