lock OPEL FRONTERA 1998 Repair Manual

4C–15 DRIVE SHAFT SYSTEM
3. Remove bolt.
Before removal, shift transfer lever into “2H” position,
set free wheeling hub knob into “FREE” position (1),
and run the vehicle about 50m (160 ft).
411RW010
4. Remove cover assembly.
5. Remove snap ring and shim.
6. Remove body assembly.
7. Remove lock washer and lock screw.
8. Remove hub nut by using wrench 5–8840–2117–0.
411RW005
9. Remove hub and disc assembly.
10. Remove ABS sensor ring (If equipped).
11. Remove outer bearing outer race.
12. Remove oil seal.13. Remove inner bearing outer race.
14. While pushing follower knob against cover, turn clutch
assembly clockwise and then remove clutch
assembly from knob.
411RW011
15. Remove gasket.
16. Remove snap ring.
17. Remove knob.
18. Remove compression spring.
19. Remove follower.
20. Remove retaining spring from clutch assembly by
turning it counterclockwise.
411RW012
21. Remove dedent ball and spring.
22. Remove X–ring.
23. Remove snap ring.
24. Remove inner assembly.
25. Remove snap ring.
26. Remove ring.
27. Remove spacer.

4C–16
DRIVE SHAFT SYSTEM
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
Hub
Hub bearing, oil seal
Knuckle spindle
Disc
Caliper
Free wheeling hub parts (Clutch, knob, follower,
inner, ring and spring)
ABS sensor ring (if so equipped)
For inspection and servicing of disc caliper, and relative
parts, refer to Brakes section.
Reassembly
1. Install spacer.
Apply about 1 g wheel bearing grease to both face of
spacer.
2. Install ring.
Apply about 3 g wheel bearing grease to inside face
of ring.
3. Install snap ring
Assembly with grease surplus being left unwiped up
as illustrated.
411RW013
Legend
(1) Inner Assembly
(2) Apply Grease
(3) Body
4. Install inner assembly.
Apply grease to splined portion of body.
5. Install snap ring.6. Install X–ring.
Apply wheel bearing grease to hub lock ring and fit it
in knob paying attention to mounting direction.
NOTE: After fitting, make sure that the hub lock ring is not
twisted.
7. Apply wheel bearing grease to ball and spring and fit
them in knob.
8. Install knob.
1. Apply grease to outer circumference of knob and
inner circumference of cover.
2. Align detent ball (1) to a groove cut in the cover.
411RW014
9. Install snap ring.
Turn the smoother face to knob side.
10. Align the end of retaining spring (1) with clutch spring
groove (2) and fit in the spring.
411RW015

4C–17 DRIVE SHAFT SYSTEM
11. Install follower to clutch so that follower nails (large)
(1) will come closer to the bent portion of retaining
spring by aligning follower stopper nail with outer
teeth of clutch. Then, fit in with follower’s nails (small)
(2) caught in spring.
411RW016
12. Install compression ring.
Turn the smaller diameter side toward follower and fit
spring in clutch.
13. Align follower nail (1) to handle groove (2). and then
assemble clutch with knob by pushing and turning
clutch counterclockwise to knob.
411RW017
14. Install gasket.
Make sure that there is no breakage, etc.
15. Install outer bearing outer race by driving it into the
hub, by using installer 5–8522–2118–0 and grip
5–8840–0007–0.
411RW007
16. Install inner bearing outer race by driving it into the
hub, by using installer 5–8840–2119–0 and grip
5–8840–0007–0.
411RW006

4C–19 DRIVE SHAFT SYSTEM
21. Install lock washer and lock screw in the following
manner.
Turn the side with larger diameter of the tapered
bore to the vehicle outer side, and attach the
washer.
If the bolt holes in the lock plate are not aligned with
the corresponding holes in the nut, reverse the lock
plate.
If the bolt holes are still out of alignment, trun in the
nut just enough to obtain alignment.
Screw is to be fastened tightly so its head may
come lower than the surface of the washer.
411RS012
22. Install body assembly.
Apply adhesive (LOCTITE 515 or equivalent) to
both joining faces.
Tighten the bolts to the specified torque.
Torque:59Nꞏm (6.0kgꞏm/43lbft)
23. Install snap ring and shim.
Adjust the clearance between the free wheeling hub
body and the snap ring.
Clearance:
0-0.3mm (0-0.012in)
Shims Available:
0.2mm, 0.3mm, 0.5mm, 1.0mm, (0.008in, 0.012in,
0.020in, 0.039in)
411RW002
24. Install cover assembly.
Align stopper nails (1) to grooves of body (2).
411RW019
25. Tighten the cover bolts to the specified torque.
Torque:12Nꞏm (1.2kgꞏm/104lbin)

4C–42
DRIVE SHAFT SYSTEM
3. Make sure of proper position for reinstallation by
applying setting marks, then remove spider .
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) 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
5. Constant velocity joint
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)
401RS027
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

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).