1998 OPEL FRONTERA lock

4C–52
DRIVE SHAFT SYSTEM
3. Make sure of proper position for reinstallation by
applying setting marks, then remove spider with
grease fitting.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
NOTE: When any part of the journal assembly (spider,
needle roller bearing, grease fitting) requires
replacement, be sure to replace the entire assembly.
Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
Outside Diameter of Spider Pin
Standard: 17.00 mm (0.669 in)
Limit: 16.90 mm (0.665 in)
401RS007
Propeller Shaft Run-out
Support the ends of the propeller shaft on V-blocks (2)
and check for run-out by holding the probe of a dial
indicator (1) in contact with the center part of the shaft. If
the amount of run-out is beyond the standard value for
assembly, correct with a bench press or replace the shaft
with a new propeller shaft assembly .
Standard: 0.3 mm (0.012 in)
Limit: 0.5 mm (0.02 in)
401RS008
Play in Splines in Normal Direction of
Rotation
Check the amount of play between the sleeve yoke (1)
and the propeller shaft spline (2) in the direction of
rotation, using a pointed feeler gauge.
Standard: 0.073 – 0.156 mm (0.003 – 0.006 in)
Limit: 0.3 mm (0.012 in)
401RS009

TRANSFER CASE (STANDARD TYPE)
4D1–1
DRIVELINE/AXLE
TRANSFER CASE (STANDARD TYPE)
CONTENTS
Service Precaution 4D1–1. . . . . . . . . . . . . . . . . . . . . .
General Description 4D1–2. . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal 4D1–8. . . . . . . . . . . . . . . . . . .
Removal 4D1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly 4D1–9. . . . . . . . . . . . . . . . .
Removal 4D1–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Cover Assembly
(4WD Switch Model) 4D1–11. . . . . . . . . . . . . . . . . . . .
Transfer Rear Cover Assembly and
Associated Parts 4D1–11. . . . . . . . . . . . . . . . . . . . . .
Removal 4D1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D1–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 4D1–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4D1–17. . . . . . . . . . . . . . . . . .
Reassembly 4D1–17. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Cover Assembly
(Except 4WD Switch Model) 4D1–19. . . . . . . . . . . . . . Transfer Rear Cover Assembly and
Associated Parts 4D1–19. . . . . . . . . . . . . . . . . . . . . .
Removal 4D1–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D1–20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 4D1–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4D1–24. . . . . . . . . . . . . . . . . .
Reassembly 4D1–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Detent, Shift Arm, and Interlock Pin 4D1–26. . . . . . . .
Disassembled View 4D1–26. . . . . . . . . . . . . . . . . . . .
Disassembly 4D1–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4D1–28. . . . . . . . . . . . . . . . . .
Reassembly 4D1–28. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly 4D1–30. . . . . . . . . . . . . . . . .
Disassembled View 4D1–30. . . . . . . . . . . . . . . . . . . .
Disassembly 4D1–31. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4D1–33. . . . . . . . . . . . . . . . . .
Reassembly 4D1–37. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4D1–43. . . . . . . . . . . . .
Special Tools 4D1–46. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS 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.

4D1–20
TRANSFER CASE (STANDARD TYPE)
Removal
1. Remove the speedometer sensor.
2. Remove the plate.
3. Remove the speedometer driven gear bushing and
driven gear.
NOTE: Apply a reference mark to the driven gear bushing
before removal.
4. Remove the front companion flange and the rear
companion flange, using the flange companion holder
5–8840–0133–0 (J–8614–11) to remove the end
nuts.
262RW067
NOTE: Use a universal puller to remove the rear
companion flange.
5. Disconnect the transfer breather hose from the
control box.
6. Remove the control box assembly.
7. Remove the transfer rear cover assembly from the
transfer case assembly.
Installation
1. Apply the recommended liquid gasket (LOCTITE
17430) or its equivalent to the transfer rear cover
fitting faces.
220RS017
2. Install the transfer rear cover assembly to the transfer
case assembly.
3. Perform the following steps before fitting the transfer
rear case:
1. Shift the high–low shift rod to the 4H side.
2. Turn the select rod counterclockwise so that the
select block projection may enter into the
2WD–4WD shift block.
3. The cut–away portion of the select rod head (9)
should align with that of the rear case hole’s
stopper (10).
230RW004
4. Tighten the transfer rear case bolts to the specified
torque.
Torque: 37 Nꞏm (3.8kgꞏm/27 lb ft)

4D1–26
TRANSFER CASE (STANDARD TYPE)
Detent, Shift Arm, and Interlock Pin
Disassembled View
262RW074
Legend
(1) Detent Ball, Spring and Plug
(2) Spring Pin and Bridge
(3) Spring Pin
(4) Spring
(5) 2WD–4WD Shift Rod
(6) Shift Arm
(7) Shift Block
(8) 4WD Indicator Switch(9) Interlock Pin
(10) Spring
(11) Select Rod Assembly
(12) Spring Pin
(13) High–Low Shift Rod
(14) Shift Arm
(15) Shift Block
(16) Transfer Case
(17) Spring (Except Shift On The Fly Model)
Disassembly
1. Remove the detent ball, spring and plug (1).

TRANSFER CASE (STANDARD TYPE)
4D1–27
2. Use a spring pin remover to remove the spring pin (2)
from the bridge (2).
262RW011
3. Remove the spring (4).
4. Engage the 2WD–4WD sleeve with the front output
gear. Remove the spring pin (3) from the block (7).
Remove the 2WD–4WD shift rod (5).
262RW022
5. Remove the shift arm (6).
6. Remove the shift block (7).
7. Remove the 4WD indicator switch (8).8. Use a magnetic tool to remove the interlock pin (9)
and spring (10) from the transfer case (16).
262RS005
9. Remove the select rod assembly (11).
10. Use a spring pin remover to remove the shift arm
spring pins (12) from the shift arm (14) and shift block
(15). Remove the high–low shift rod (13) from the
transfer case (16).
262RS006
11. Remove the shift arm (14).
12.Remove the shift block (15) from the transfer case
(16).

4D1–28
TRANSFER CASE (STANDARD TYPE)
Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Place the shift block (15) in the transfer case (16).
2. Set the shift arm (14) on the High–Low sleeve.
3. Push the High–Low shift rod (13) through the shift
arm (14) and block (14).
4. Engage the High–Low sleeve with the 4H (1) side.
5. Install the spring pins (12) to the shift block (15) and
shift arm (14).
262RW012
6 . I n s t a l l t h e s e l e c t r o d a s s e m b l y ( 11 ) , j o i n i n g i t s l e v e r t o
the shift block groove.
7. Engage the High–Low sleeve with the 4H side and
install the the interlock pin (9) and spring (10) in the
proper direction.
8. Place the 2WD–4WD shift block (7) in the transfer
case (16).
9. Set the 2WD–4WD shift arm (6) on the 2WD–4WD
sleeve.
10. Push the 2WD–4WD shift rod (5) through the
2WD–4WD shift arm (6) and 2WD–4WD shift block
(7).
11. Install the 2WD–4WD shift rod (5) with the interlock
pin pushed in.
262RW035
Legend
(18) 2WD–4WD
(19) 4H Side
(20) Interlock pin
(21) 2WD
(22) 4WD
(23) Rod: 2–4
(24) Rod: H–L
(25) 4H
(26) 4L
(27) 4
2
(28) 4
4
12. Install the 4WD indicator switch and gasket (8).
Tighten to the specified torque.
Torque: 39 Nꞏm (4.0kgꞏm/29 lb ft)
13. Install the spring (4).

4D1–30
TRANSFER CASE (STANDARD TYPE)
Transfer Case Assembly
Disassembled View
226RW132
Legend
(1) Transfer Case (with oil seal)
(2) Bearing Snap Ring
(3) Front Output Gear Assembly
(4) Ball Bearing
(5) Front Output Shaft
(6) Stopper Plate (Shift On The Fly model)
(7) 2WD–4WD Clutch Hub and Sleeve Assembly
(8) Block Ring (Shift On The Fly model)
(9) Outside Ring (Shift On The Fly model)
(10) Inside Ring (Shift On The Fly model)
(11) Front Output Gear
(12) Needle Bearing
(13) Sub–Gear (anti–lash plate) (M/T)
(14) Belleville Spring (M/T)
(15) Spacer (M/T)
(16) Sub–Gear Snap Ring (M/T)
(17) Bearing Collar
(18) Ball Bearing
(19) Bearing Snap Ring
(20) Snap Ring
(21) Ball Bearing(22) Counter Gear
(23) Sub–Gear (anti–lash plate)
(24) Belleville Spring
(25) Spacer
(26) Ball Bearing
(27) Snap Ring
(28) Counter Gear Assembly
(29) Bearing Snap Ring
(30) Input Shaft Assembly
(31) Input Shaft
(32) Ball Bearing
(33) Snap Ring
(34) Plate
(35) Ball
(36) Bearing Collar
(37) Needle Bearing
(38) Transfer Input Gear
(39) High–Low Clutch Hub and Sleeve Assembly
(40) Lock Nut
(41) Ball Bearing
(42) Bearing Snap Ring

TRANSFER CASE (STANDARD TYPE)
4D1–31
Disassembly
1. Use a pair of snap ring pliers to remove the snap ring
(42).
2. Use a bearing remover 5–8840–2155–0 ( J–37217)
and puller 5–8840–2027–0 (J–37487) to remove the
ball bearing (41).
262RW069
3. Install the front companion flange temporarily.
4. Use the Companion flange holder 5–8840–0133–0
(J–8614–11) and lock nut wrench 5–8840–2156–0
(J–37219) to remove the lock nut (40).
226RW189
5. Remove the front companion flange.
6. Remove the snap ring (33) from the transfer case (1).
7. Remove the input shaft assembly (30) from the
transfer case.
265RW001
8. Use a universal puller to remove the high–low clutch
hub and sleeve (39), and transfer input gear (38).
226RS070
9. Remove needle bearing (37).