1998 OPEL FRONTERA oil

4D1–16
TRANSFER CASE (STANDARD TYPE)
Disassembly
226RW154
Legend
(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing(5) Bearing Snap Ring
(6) Ball
(7) Speedometer Drive Gear
(8) Ball Bearing
(9) Transfer Rear Cover (with oil seal)
1. Remove the bearing snap ring (3), using a pair of snap
ring pliers.
226RS060

TRANSFER CASE (STANDARD TYPE)
4D1–17
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5–8840–0015–0 (J–22912–01) .
226RW186
4. Remove the speedometer drive gear (7).
5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01).
226RW187
Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Install transfer rear cover (with oil seal).
Oil seal replacement
Remove the oil seal from the transfer rear cover.
Apply engine oil to the oil seal outer surfaces.
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.
220RW104
2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).
262RW068

TRANSFER CASE (STANDARD TYPE)
4D1–23
Disassembly
226RW154
Legend
(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing(5) Bearing Snap Ring
(6) Ball
(7) Speedometer Drive Gear
(8) Ball Bearing
(9) Transfer Rear Cover (with oil seal)
1. Remove the bearing snap ring (3), using a pair of snap
ring pliers.
226RS060

4D1–24
TRANSFER CASE (STANDARD TYPE)
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5–8840–0015–0 (J–22912–01) .
226RW186
4. Remove the speedometer drive gear (7).
5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01).
226RW187
Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Install transfer rear cover (with oil seal).
Oil seal replacement
Remove the oil seal from the transfer rear cover.
Apply engine oil to the oil seal outer surfaces.
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.
220RW104
2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).
262RW068

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)
4D1–33
NOTE: Do not reuse the stopper plate. (Shift On The Fly
model)
24. Disassemble the 2WD–4WD clutch hub and sleeve
assembly.
Springs (1) (Shift On The Fly model)
Inserts (2) (Shift On The Fly model)
Clutch Hub (3)
Sleeve (4)
226RW133
25. Use a bench press and the ball bearing remover
5–8840–0015–0 (J–22912–01) to remove the ball
bearing (4) from front output shaft (5).
262RW071
26. Remove bearing snap ring (29) from transfer case.
27. Remove the counter gear assembly (28) from the
transfer case (1).
28. Use a pair of snap ring pliers to remove the snap ring
(20).29. Use a bench press and the bearing remover
5–8840–0015–0 (J–22912–01) to remove the ball
bearing (21).
30. Use a pair of snap ring pliers to remove the snap ring
(27).
31. Use a bench press and the bearing remover
5–8840–0015–0 (J–22912–01) to remove the ball
bearing (26).
226RW191
32. Remove the spacer (25).
33. Remove the belleville spring (24).
34. Remove the sub–gear (anti–lash plate) (23) from the
counter gear (22).
Inspection and Repair
1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and
channel in each case half to remove any obstructions
or cleaning solvent residue.
Gears
1. Inspect all the gear teeth for signs of excessive wear
or damage and check all the gear splines for burrs,
nicks, wear or damage. Remove the minor nicks or
scratches on an oil stone. Replace any part exhibiting
excessive wear or damage.
Front Output Gear Inside Diameter
1. Use an inside dial indicator to measure the gear inside
diameter.

4D1–34
TRANSFER CASE (STANDARD TYPE)
2. If the measured value exceeds the specified limit, the
gear must be replaced.
Gear inside diameter
Standard : 48.000–48.013 mm (1.8898–1.8903 in)
Limit : 48.10 mm (1.894 in)
226RS040
Clutch Hub Spline Play
1. Set a dial indicator to the clutch hub to measured.
2. Move the clutch hub as far as possible to both the right
and the left.
Note the dial indicator reading.
3. If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Clutch hub spline play
Standard : 0–0.1 mm (0–0.004 in)
Limit : 0.2 mm (0.008 in)
226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)
226RS043
Synchronizers
The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
Teeth for wear, scuffs, nicks, burrs or breaks.
Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace the
component.
Block Ring and Insert Clearance
1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limit, the
block ring and the insert must be replaced.
Block ring and insert clearance
Standard : 2.46–2.74 mm (0.097–0.108 in)

TRANSFER CASE (STANDARD TYPE)
4D1–37
Reassembly
1. Put the transfer case (with oil seal) as the following
illustration.
Input shaft oil seal (1) replacement
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5–8840–2279–0
(J–38592) to install the oil seal to the transfer
case.
220RW106
Front output shaft oil seal (2) replacement
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5–8840–2281–0
(J–38594) to install the oil seal to the transfer
case.
220RW107
Legend
(2) Front output shaft oil seal
2. Apply chassis grease (3) to the sub–gear (23) and the
counter gear (22) thrust surfaces.
226RW134