1998 OPEL FRONTERA Workshop Manual

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Page 753 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D1–32
TRANSFER CASE (STANDARD TYPE)
10. Remove the bearing collar (36).
226RS071
11. Remove the ball (35).
12. Remove the plate (34).
13. Use a bench press and the ball bearing remover
5–

Page 754 of 6000

OPEL FRONTERA 1998 Workshop Manual 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

Page 755 of 6000

OPEL FRONTERA 1998 Workshop Manual 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 :

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)

Page 756 of 6000

OPEL FRONTERA 1998 Workshop Manual TRANSFER CASE (STANDARD TYPE)
4D1–35
Limit : 3.0 mm (0.118 in)
226RS037
2WD–4WD 3–Cone Synchronizer (Shift On
The Fly model)
1. Use a thickness gauge to measure the clearance
between the

Page 757 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D1–36
TRANSFER CASE (STANDARD TYPE)
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard : 23.4 mm (0.921 in

Page 758 of 6000

OPEL FRONTERA 1998 Workshop Manual 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 tr

Page 759 of 6000

OPEL FRONTERA 1998 Workshop Manual 4D1–38
TRANSFER CASE (STANDARD TYPE)
3. Install the sub–gear (23) to the counter gear (22).
4. Install the belleville spring (24).
5. Install the spacer (25) and put the snap ring (29) on
the sub�

Page 760 of 6000

OPEL FRONTERA 1998 Workshop Manual TRANSFER CASE (STANDARD TYPE)
4D1–39
14. Assemble the 2WD–4WD clutch hub and sleeve
assembly (7).
226RW140
15. Engage the springs in the same insert with the open
ends away from each other.

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