1998 OPEL FRONTERA Workshop Manual

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Page 4305 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D1–44
TRANSFER CASE (STANDARD TYPE)
E07RW039

Page 4306 of 6000

OPEL FRONTERA 1998 Workshop Manual TRANSFER CASE (STANDARD TYPE)
4D1–45
E07RW038

Page 4307 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D1–46
TRANSFER CASE (STANDARD TYPE)
Special Tools
ILLUSTRATIONPA R T N O .
PA R T N A M E
5–8840–0015–0
(J–22912–01)
Bearing
remover/installer
5–8840–2279–0
(J–38592)
Transfer

Page 4308 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–1 TRANSFER CASE (TOD)
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution 4D2–1. . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly 4D2–2. . . . . . . . . . . . . .

4D2–1 TRANSFER CASE (TOD)
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution 4D2–1. . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly 4D2–2. . . . . . . . . . . . . . . . .
Removal 4D2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal 4D2–5. . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal and Associated
Parts 4D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 4D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU 4D2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 4D2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 4D2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 4D2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case 4D2–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–9. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–10. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Cover Assembly 4D2–12. . . . . . . . . . . . . . . .
Disassembled View 4D2–12. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–12. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–14. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly Clutch Pack and
Clutch Cam 4D2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–16. . . . . . . . . . . . . . . . . . . . Disassembly 4D2–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock 4D2–18. . . . . . . . . . . .
Disassembled View 4D2–18. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–18. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft 4D2–20. . . . . .
Disassembled View 4D2–20. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case 4D2–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–23. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4D2–26. . . . . . . . . . . . . . . . . .
Transfer Case 4D2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–30. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft 4D2–34. . . . . .
Disassembled View 4D2–34. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–34. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock 4D2–37. . . . . . . . . . . .
Disassembled View 4D2–37. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–37. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pack and Clutch Cam 4D2–39. . . . . . . . . . . . .
Disassembled View 4D2–39. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–39. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4D2–41. . . . . . . . . . . . .
Special Tools 4D2–43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

Page 4309 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–2
TRANSFER CASE (TOD)
Transfer Case Assembly
Removal
F07RW083
Legend
(1) Transfer Protector
(2) Rear Propeller Shaft
(3) Front Propeller Shaft
(4) Front Console
(5) Selector Lever Assembly
(6) T

Page 4310 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–3 TRANSFER CASE (TOD)
6. Disconnect the wiring harness connector, transfer
control lever knob and shift lock cable and then
remove the front console.
7 . R e m o v e t h e s e l e

Page 4311 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–4
TRANSFER CASE (TOD)
3. Tighten the transfer case bolts (see the figure below).
Torque : 46 Nꞏm (4.7 kgꞏm/34 lb ft)
261RW004–1
4. Tighten the propeller shaft bolts.
Torque : 63 Nꞏm (6.4

Page 4312 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–5 TRANSFER CASE (TOD)
Transfer Rear Oil Seal
Transfer Rear Oil Seal and Associated Parts
261RW005
Legend
(1) Oil Seal
(2) End Nut and Rear Companion Flange
Removal
1. Remove the rear propelle

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