1998 OPEL FRONTERA rack

TRANSFER CASE (STANDARD TYPE)
4D1–35
Limit : 3.0 mm (0.118 in)
226RS037
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)
226RW142
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)
226RS038
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.

4D2–6
TRANSFER CASE (TOD)
2. Using the oil seal installer 5-8840-2412-0 (J-42804),
install the oil seal.
NOTE: When installing the oil seal, pay attention to the
direction.
261RW051
Rear 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 : 9.85 — 10.35mm (0.39 — 0.41 in)
A04RW004
3. Mount the rear companion flange, O-ring , washer,
and nut to the transfer case in this order.
4. Using the flange holder 5-8840-0133-0 (J-8614-11),
install a new end nut.
Torque : 167 Nꞏm (17 kgꞏm /123 lb ft)
5. Using the punch 5-8840-2293-0 (J-39209), stake the
end nut at two spots.
NOTE: Check the staked end nut is free from cracks.
266RW028
260RW007
6. Install the rear propeller shaft to the transfer case and
tighten to the specified torque.
Torque : 63 Nꞏm (6.4 kgꞏm /46 lb ft)

4D2–7 TRANSFER CASE (TOD)
TOD ECU
Removal
1. Disconnect the ground cable.
2. Move the right-hand seat forward and remove the
second seat foot rest (1).
3. Disconnect the connector from the ECU (2).
4. Remove the bolts and detach the ECU (2) from the
bracket.
F07RW021
Installation
1. Perform the removal step in reverse order.

4D2–11 TRANSFER CASE (TOD)
2. Tighten the sixteen bolts to the specified torque.
Torque : 31 Nꞏm (3.2 kgꞏm/23 lb ft)
3. Wind the sealing tape around the drain plug thread
and tighten the plug to the specified torque.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
4. Mount the offset lever to the transfer shift and install
the spring pin.
261RW016
5. Attach the O-ring and washer to the companion
flange.
NOTE: Securely push the O-ring to the hollow of the
companion flange, and then attach the washer.
6. Use the flange holder 5-8840-0133-0 (J-8614-11) to
tighten the flange nut.
7. Tighten the flange nut to the specified torque.
Torque : 167 Nꞏm (17.0 kgꞏm/123 lb ft)
8. Using the punch 5-8840-2293-0 (J-39209), securely
stake the flange nut at two spots.
NOTE: Check the staked flange nut is free from cracks.
266RW028
260RW007
9. Fix the harness with the clip.
10. Tighten the 4L and 4H switch to the specified torque.
Torque : 24 Nꞏm (2.4 kgꞏm/17 lb ft)
11. Fill the transfer case with ATF II or III (1.9 liters).
12. Wind the sealing tape around the filler plug thread and
tighten the plug to the specified torque.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)

4D2–27 TRANSFER CASE (TOD)
Reduction Fork
Check the reduction fork and shaft for wear, distortion,
and scratches. If defects are observed, replace the
parts.
Thickness of Reduction Fork
If the measurement exceeds the limit, replace the
reduction fork.
Standard : 3.41-3.79 mm (0.134-0.149 in)
Allowable limit : 4.4 mm (0.173 in)
261RW026
Lock-up Fork
Check the lock-up fork and shaft for wear, distortion,
and scratches. If defects are observed, replace the
parts.
Thickness Lock-up Fork
If the measurement exceeds the limit, replace the
lock-up fork.
Standard : 6.99-7.09 mm (0.275-0.279 in)
Allowable limit : 6.3 mm (0.248 in)
261RW027
Bearing
Check the profile of the needle, roller, ball, and thrust
bearings. Wash the bearings with clean solvent
completely, and dry with air.
NOTE: If the bearing is rotated excessively, the rollers
may be damaged. So, rotate the bearing slowly with your
hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
with your hand.
Use a dial indicator to measure the ball bearing play.
Allowable limit : 0.23 mm (0.009 in)
226RW143
Lock-up Fork Spring
Check the lock-up fork spring for distortion, cracking,
and wear. If defects are observed, replace the part.
Free Length of the Lock-up Fork Spring
If the measurement exceeds the limit, replace the
spring.
Standard : 60.96 mm (2.40 in)
Allowable limit : 55.0 mm (2.17 in)
220RW045

5A–45 BRAKE CONTROL SYSTEM
Chart B-5 G-Sensor Circuit (DTC 21)
StepActionYe sNo
1Vehicle placed horizontal.
Is the resistance between the G sensor connector terminals 1 and
2 within 4.0-6.0 k
?
Check harness
connector for
short.
Fault found :
Repair , and
perform system
self-check.
No fault found :
replace EHCU.
Go to Step 3
Go to Step 2
2Is the bracket installed horizontally?
Go to Step 4
Repair or replace
bracket.
Go to Step 4
3Remove G sensor.
Is the resistance between the G sensor connector terminals 1 and
2 within 1.0-2.0 k
when G sensor is horizontal?Go to Step 4
Replace G
sensor.
Go to Step 5
4Measure resistance between G sensor connector terminals 1 and
2 within 4.0-6.0 k
when G sensor tilted to 30 or more?
Harness between
EHCU and G
sensor is faulty
and short.
Repair the
harness
Go to Step 5
Replace G
sensor.
Go to Step 5
51. Reconnect all components and ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Repeat the “Basic
diagnostic flow
chart.”
Go to Step 5

5B–4ANTI–LOCK BRAKE SYSTEM
Front Wheel Speed Sensor
Front Wheel Speed Sensor and Associated Parts
350RW012
Legend
(1) Speed Sensor Connector
(2) Sensor Cable Fixing Bolt (Upper side)(3) Sensor Cable Fixing Bolt (Lower side)
(4) Sensor Cable Fixing Bolt (Sensor side)
(5) Speed Sensor
Removal
1. Remove speed sensor connector.
2. Remove sensor cable fixing bolt (Upper side).
3. Remove sensor cable fixing bolt (Lower side).
4. Remove the speed sensor cable fixing bolts (1) and
caliper fixing bolt (2) from caliper side speed sensor
cable bracket (3).
350RW010
5. Remove speed sensor.

5B–5 ANTI–LOCK BRAKE SYSTEM
Inspection and Repair
1. Check the speed sensor pole piece for presence of
foreign materials; remove any dirt, etc.
2. Check the pole piece for damage; replace speed
sensor if necessary.
3. Check the speed sensor cable for short or open
circuit, and replace with a new one if necessary.
To check for cable short or open, bend or stretch the
cable while checking for continuity.
4. Check the sensor ring for damage including tooth
chipping, and if damaged, replace the sensor ring
assembly. Refer to Front Hub and Disc in Drive Shaft
System section.
Installation
1. Install speed sensor and take care not to hit the speed
sensor pole piece during installation.
2. Install speed sensor fixing bolt and tighten the fixing
bolt to the specified torque.
Torque
Sensor side : 8 Nꞏm (0.8kgꞏm/69 lb in)
Caliper side : 155 Nꞏm (15.8kgꞏm/115 lb ft)
350RW011
Legend
(1) Caliper Fixing Bolt
(2) Bracket
(3) Sensor Fixing Bolt
(4) Sensor
(5) Knuckle
(6) Brake Caliper
3. Install speed sensor cable fixing bolt (Lower side) and
tighten the fixing bolt to the specified torque.
Torque : 24 Nꞏm (2.4kgꞏm/18 lb ft)
4. Install speed sensor cable fixing bolt (Upper side) and
tighten the fixing bolt to the specified torque.
Torque : 6 Nꞏm (0.6kgꞏm/52 lb in)NOTE: Confirm that a white line marked on the cable is
not twisted when connecting the speed sensor cable.
5. Install speed sensor connector.