1998 OPEL FRONTERA Workshop Manual

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Page 4329 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–22
TRANSFER CASE (TOD)
13. Using snap ring pliers, remove the snap ring from the
shifter shaft assembly.
261RW021
14. Remove the reduction lever assembly.
15. Remove the snap ring.
16. Remove th

Page 4330 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–23 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 B

Page 4331 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–24
TRANSFER CASE (TOD)
Disassembly
1. Remove the ball bearing (for front output shaft).
2. Expand the snap ring through the opening in the
planetary gear assembly.
261RW040
3. While exp

Page 4332 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–25 TRANSFER CASE (TOD)
6. Using the bearing remover 5-8840-0015-0
(J-22912-01), remove the ball bearing from the input
shaft.
265RW014
7. Remove the thrust plate.
8. Remove the carrier assem

Page 4333 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D2–26
TRANSFER CASE (TOD)
265RW007
Inspection and Repair
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all th

4D2–26
TRANSFER CASE (TOD)
265RW007
Inspection and Repair
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean solvent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.
Chain
Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.
If the chain interference mark is found on the inside
w a l l o f t h e t r a n s f e r c o v e r o r t h e c h a i n i s s o s l a c k t h a t a
skipped engagement occurs between the chain and
sprocket, replace the chain.
Sprocket
Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.
Gear
Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
Thickness of Reduction Hub
Measure the thickness with a micrometer.
If the measurement exceeds the limit, replace the
reduction hub.
Standard : 3.05-3.30 mm (0.120-0.130 in)
Allowable limit : 2.5 mm (0.098 in)
265RW005
Lock-up Sleeve
Mount the mechanical lock hub, drive sprocket
assembly, and lock-up sleeve to the output shaft.
If the lock-up sleeve does not move smoothly, replace
the sleeve.
NOTE: Apply ATF to the area engaging the gear.
Thickness of Lock-up Sleeve
If the measurement exceeds the limit, replace the
lock-up sleeve.
Standard : 7.16-7.32 mm (0.282-0.288 in)
Allowable limit : 7.9 mm (0.311 in)
266RW014

Page 4334 of 6000

OPEL FRONTERA 1998 Workshop Manual 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 mea

Page 4335 of 6000

OPEL FRONTERA 1998 Workshop Manual 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

Page 4336 of 6000

OPEL FRONTERA 1998 Workshop Manual 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.
266RW016
The Parts 4H and 4L Switch

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