1998 OPEL FRONTERA engine oil

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–116
StepActionYe sNo
1Are the front and rear tires in specified size?
Go to Step 2
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
2Is the tire pressure correct?
Go to Step 3
In flate tries to
recommended
pressure.
Go to Step 16
3Are the tires free from abnormal wear?
Go to Step 4
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
4Are different types of tires used?
Go to Step 5
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
51. Start the engine.
2. Shift the transfer lever to the high position and switch the 4WD
AUTO SW to 4WD position.
3. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 6 Go to Step 11
61. Shift the transfer lever to the high position and switch the 4WD
AUTO SW to the 2H position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 7 Go to Step 14
7Is an LSD mounted to the rear differential? Go to Step 8 Go to Step 9
8Is the genuine LSD oil used in the rear differential?
Go to Step 9
Replace the
differential oil.
Go to Step 16
9Does the engine output the power correctly?
Go to Step 10
Check the
engine.
Go to Step 16
10Do the speed sensors work correctly? (Check trouble codes.)The ECU has
failed. Replace
the ECU.
Go to Step 16
Replace the
speed sensors.
Go to Step 16
11Is the tight corner braking observed only when the brake is
applied?
Go to Step 12
Conduct full
steering under
WOT.
Go to Step 5
121. Turn on the starter switch.
Is the battery voltage observed between terminals 11 and 19?
Go to Step 13
Repair the circuit
of terminal 11
(ABS IN).
Go to Step 16

4D1–8
TRANSFER CASE (STANDARD TYPE)
Transfer Rear Oil Seal
Removal
1. Disconnect the rear propeller shaft from the transfer
case side.
2. Remove end nut and rear companion flange, using
the companion flange holder 5–8840–0133–0
(J–8614–11).
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3. Use the universal puller to remove the rear
companion flange and O–ring.
4. Remove the oil seal from the transfer case.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install oil seal and apply engine oil to the oil seal outer
surfaces.
2. Apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
3. Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear seal to the transfer rear case.
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4. Install the rear companion flange and O–ring.
5. Use the companion flange holder 5–8840–0133–0
(J–8614–11) to install a new end nut and tighten to the
specified torque.
Torque: 167 Nꞏm (17.0kgꞏm/123 lb ft)
6. Use the punch 5–8840–2293–0 (J–39209) to stake
the end nut at two spots.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the end nut after staking.
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TRANSFER CASE (STANDARD TYPE)
4D1–17
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5–8840–0015–0 (J–22912–01) .
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4. Remove the speedometer drive gear (7).
5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01).
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Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Install transfer rear cover (with oil seal).
Oil seal replacement
Remove the oil seal from the transfer rear cover.
Apply engine oil to the oil seal outer surfaces.
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.
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2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).
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4D1–24
TRANSFER CASE (STANDARD TYPE)
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5–8840–0015–0 (J–22912–01) .
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4. Remove the speedometer drive gear (7).
5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01).
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Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Install transfer rear cover (with oil seal).
Oil seal replacement
Remove the oil seal from the transfer rear cover.
Apply engine oil to the oil seal outer surfaces.
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.
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2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).
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TRANSFER CASE (STANDARD TYPE)
4D1–37
Reassembly
1. Put the transfer case (with oil seal) as the following
illustration.
Input shaft oil seal (1) replacement
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5–8840–2279–0
(J–38592) to install the oil seal to the transfer
case.
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Front output shaft oil seal (2) replacement
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5–8840–2281–0
(J–38594) to install the oil seal to the transfer
case.
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Legend
(2) Front output shaft oil seal
2. Apply chassis grease (3) to the sub–gear (23) and the
counter gear (22) thrust surfaces.
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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
262RS015
226RS021

TRANSFER CASE (STANDARD TYPE)
4D1–43
Main Data and Specifications
General Specifications
Ty p eW/Shift On The Fly System model
Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Constant mesh type gears shifting between “low” and “high”.
WO/Shift On The Fly System model
Constant mesh type gears shifting between the 2 and 4 wheel drive mode,
and between “low” and “high”.
Control methodW/4WD Switch model
Electric control with the button switch on the instrument panel for gear
shifting between the 2 and 4 wheel drive mode.
Remote control with the gear shift lever on the floor for gear shifting
between “low and high” .
WO/4WD Switch model
Remote control with the gear shift lever on the floor for gear shifting.
Gear ratioHigh; 1.000
Low; 2.050
Oil capacity1.45 lit. (1.53 U.S. quart)
Type of lubricantEngine oil
Refer to chart in Section 0
Torque Specifications
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4D2–5 TRANSFER CASE (TOD)
Transfer Rear Oil Seal
Transfer Rear Oil Seal and Associated Parts
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Legend
(1) Oil Seal
(2) End Nut and Rear Companion Flange
Removal
1. Remove the rear propeller shaft from the transfer
case.
2. Using the flange holder 5-8840-0133-0 (J-8614-11),
remove the end nut.
3. Using the universal puller, remove the rear
companion flange, washer and O-ring.
4. Remove the oil seal from the transfer rear case.
Installation
1. Apply engine oil to the oil seal outer surfaces. Fill the
oil seal lip with grease (Besco L2).
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Legend
(1) Inside
(2) Outside