1998 OPEL FRONTERA Workshop Manual

Page 4321 of 6000

OPEL FRONTERA 1998  Workshop Manual 4D2–14
TRANSFER CASE (TOD)
6. Using the bearing remover 5-8840-2409-0 (J-42805)
and  slide  hammer  5-8840-0084-0  (J-2619-01),
remove the ball bearing for the front output shaft.
901RW234
7. Remove

Page 4322 of 6000

OPEL FRONTERA 1998  Workshop Manual 4D2–15 TRANSFER CASE (TOD)
4. Apply  a  thin  coat  of  grease  to  the  seal  ring  of  each
front and rear speed sensor, and mount the sensors
carefully.
5. Tighten the bolts to the specified torq

Page 4323 of 6000

OPEL FRONTERA 1998  Workshop Manual 4D2–16
TRANSFER CASE (TOD)
Transfer Case Assembly Clutch Pack and Clutch Cam
Disassembled View
266RW006
Legend
(1) Clutch Pack Assembly
(2) Insulator Washer
(3) Armature Plate
(4) Snap Ring(5) Wave

Page 4324 of 6000

OPEL FRONTERA 1998  Workshop Manual 4D2–17 TRANSFER CASE (TOD)
4. Remove the cam pulley.
5. Remove the wave spring.
6. Using snap ring pliers, remove the snap ring.
NOTE: Be careful not to damage the snap ring.
266RW009
7. Remove the

Page 4325 of 6000

OPEL FRONTERA 1998  Workshop Manual 4D2–18
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)

Page 4326 of 6000

OPEL FRONTERA 1998  Workshop Manual 4D2–19 TRANSFER CASE (TOD)
3.Remove the drive sprocket, lower driven sprocket,
and  chain  together  from  the  front  and  rear  output
shafts.
266RW010
4. Remove the mechanical lock hub.
5. Remove

Page 4327 of 6000

OPEL FRONTERA 1998  Workshop Manual 4D2–20
TRANSFER CASE (TOD)
Output Shafts and Shift Control Shaft
Disassembled View
261RW010–1
Legend
(1) Transfer Case Assembly
(2) Detent Spring
(3) Front Output Shaft
(4) Reduction Hub
(5) Outpu

Page 4328 of 6000

OPEL FRONTERA 1998  Workshop Manual 4D2–21 TRANSFER CASE (TOD)
Disassembly
1. Remove the output shaft.
266RW011
2. Remove the detent spring.
3. Remove the cam pilot block bolts.
4. Remove  the  shifter  shaft  assembly  and  cam
assem