oil 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 : 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

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. (Shift On The Fly model)
226RW141
16. Place the snap ring (2), a new stopper plate (6) (Shift
On The Fly model) and the clutch sleeve and hub
assembly (7) on the front output shaft (5).
226RW135
Legend
(6) Front Output Gear
17. The clutch hub face (with the heavy boss) must be
facing the front output gear side.
18. Use a bench press to slowly force the clutch hub and
sleeve assembly (7) together with the stopper plate
(6) (Shift On The Fly model) into place.
19. Align the inserts with the block ring insert grooves.
Install the block ring (8) (Shift On The Fly model) to
the clutch sleeve and hub assembly (7).
20. Install the outside ring (9) (Shift On The Fly model),
inside ring (10) (Shift On The Fly model) and needle
bearing (12) to the front output gear (11) and bearing
collar (17).
NOTE: Coat all parts with transmission oil before
installing them.
226RW139

4D1–40
TRANSFER CASE (STANDARD TYPE)
21. Apply engine oil to the thrust surfaces of the sub–gear
(13), the belleville spring (14), and the spacer (15).
(M/T)
262RW060
22. Install the sub–gear (anti–lash plate) (13), belleville
spring (14), and spacer (15) to the front output gear
(11).(M/T)
23. Install the sub–gear snap ring (16). (M/T)
24. Use a bench press to install the needle bearing collar
(17) together with the front output gear, aligning inside
ring claw with block ring groove.
262RS014
25. Install ball bearing (18), using a bench press.26. Select a snap ring that will allow the minimum axial
play.
Clearance : 0–0.1 mm (0–0.004 in)
Snap ring availability:
Snap ring thicknessColor coding
1.55 mm (0.061 in)White
1.60 mm (0.063 in)Ye l l o w
1.65 mm (0.065 in)Blue
1.70 mm (0.067 in)Pink
1.75 mm (0.069 in)Green
1.80 mm (0.071 in)Brown
1.85 mm (0.073 in)Red
1.90 mm (0.075 in)Orange
262RS015
226RS021

TRANSFER CASE (STANDARD TYPE)
4D1–43
Main Data and Specifications
General Specifications
Ty p eW/Shift On The Fly System model
Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Constant mesh type gears shifting between “low” and “high”.
WO/Shift On The Fly System model
Constant mesh type gears shifting between the 2 and 4 wheel drive mode,
and between “low” and “high”.
Control methodW/4WD Switch model
Electric control with the button switch on the instrument panel for gear
shifting between the 2 and 4 wheel drive mode.
Remote control with the gear shift lever on the floor for gear shifting
between “low and high” .
WO/4WD Switch model
Remote control with the gear shift lever on the floor for gear shifting.
Gear ratioHigh; 1.000
Low; 2.050
Oil capacity1.45 lit. (1.53 U.S. quart)
Type of lubricantEngine oil
Refer to chart in Section 0
Torque Specifications
E07RW037

4D1–46
TRANSFER CASE (STANDARD TYPE)
Special Tools
ILLUSTRATIONPA R T N O .
PA R T N A M E
5–8840–0015–0
(J–22912–01)
Bearing
remover/installer
5–8840–2279–0
(J–38592)
Transfer case oil seal
installer
5–8840–2156–0
(J–37219)
Mainshaft nut wrench
5–8840–2159–0
(J–37223)
Rear output shaft and
bearing installer
5–8840–2293–0
(J–39209)
Punch, end nut
5–8840–2281–0
(J–38594)
Front output shaft oil
seal installer
ILLUSTRATIONPART NO.
PA R T N A M E
5–8840–2292–0
(J–39208)
Rear oil seal installer
5–8840–2192–1
(J–37486–A)
Bearing installer adapter
5–8840–0133–0
(J–8614–11)
Flange holder
5–8840–2155–0
(J–37217)
Mainshaft end bearing
remover
5–8840–2027–0
(J–37487)
Puller
5–8840–0007–0
(J–8092)
Driver handle

4D2–1 TRANSFER CASE (TOD)
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution 4D2–1. . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly 4D2–2. . . . . . . . . . . . . . . . .
Removal 4D2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal 4D2–5. . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal and Associated
Parts 4D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 4D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU 4D2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 4D2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 4D2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 4D2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case 4D2–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–9. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–10. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Cover Assembly 4D2–12. . . . . . . . . . . . . . . .
Disassembled View 4D2–12. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–12. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–14. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly Clutch Pack and
Clutch Cam 4D2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–16. . . . . . . . . . . . . . . . . . . . Disassembly 4D2–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock 4D2–18. . . . . . . . . . . .
Disassembled View 4D2–18. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–18. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft 4D2–20. . . . . .
Disassembled View 4D2–20. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case 4D2–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–23. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4D2–26. . . . . . . . . . . . . . . . . .
Transfer Case 4D2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–30. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft 4D2–34. . . . . .
Disassembled View 4D2–34. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–34. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock 4D2–37. . . . . . . . . . . .
Disassembled View 4D2–37. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–37. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pack and Clutch Cam 4D2–39. . . . . . . . . . . . .
Disassembled View 4D2–39. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–39. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4D2–41. . . . . . . . . . . . .
Special Tools 4D2–43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH 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.

4D2–5 TRANSFER CASE (TOD)
Transfer Rear Oil Seal
Transfer Rear Oil Seal and Associated Parts
261RW005
Legend
(1) Oil Seal
(2) End Nut and Rear Companion Flange
Removal
1. Remove the rear propeller shaft from the transfer
case.
2. Using the flange holder 5-8840-0133-0 (J-8614-11),
remove the end nut.
3. Using the universal puller, remove the rear
companion flange, washer and O-ring.
4. Remove the oil seal from the transfer rear case.
Installation
1. Apply engine oil to the oil seal outer surfaces. Fill the
oil seal lip with grease (Besco L2).
261RW006
Legend
(1) Inside
(2) Outside

4D2–6
TRANSFER CASE (TOD)
2. Using the oil seal installer 5-8840-2412-0 (J-42804),
install the oil seal.
NOTE: When installing the oil seal, pay attention to the
direction.
261RW051
Rear Output Shaft Oil Seal
Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
Distance : 9.85 — 10.35mm (0.39 — 0.41 in)
A04RW004
3. Mount the rear companion flange, O-ring , washer,
and nut to the transfer case in this order.
4. Using the flange holder 5-8840-0133-0 (J-8614-11),
install a new end nut.
Torque : 167 Nꞏm (17 kgꞏm /123 lb ft)
5. Using the punch 5-8840-2293-0 (J-39209), stake the
end nut at two spots.
NOTE: Check the staked end nut is free from cracks.
266RW028
260RW007
6. Install the rear propeller shaft to the transfer case and
tighten to the specified torque.
Torque : 63 Nꞏm (6.4 kgꞏm /46 lb ft)

4D2–8
TRANSFER CASE (TOD)
Unit Repair
Inspection
Before disassembling and after assembling, check the
following items on the transfer connector terminals.
No.
NAMECONTENTS
1Ref . (Ref . )Rear speed sensor refer-
ence output
2Ref . (Frt . )Front speed sensor refer-
ence output
3SW GNDSW GND
44H SW (+)4H SW plus terminal
5Rer . (+)Rear speed sensor plus
6Frt . (+)Front speed sensor plus
7POWER GNDPower GND
8SOL (+)Electromagnetic solenoid
9COM (–) (Ref .)Rear speed sensor GND
10COM (–) (Frt .)Front speed sensor GND
11NC
124L SW (+)4L SW plus terminal
810RW002
4H and 4L switches
Check whether the 4H switch (terminals 4 and 7) and 4L
switch (terminals 12 and 3 ) work as specified in the table
below. If yes, the continuity is established on these
switches. If not, check the switches, shift rails, transfer
case, and rear cover, and replace the failed parts.
SHIFT POSI-
TION
PIN 4 (4 to 7)PIN 12 (3 to 12)
HIGHOFFOFF
(NEUTRAL)ONON
4LOFFON
Power GND
Check that there is a continuity between the power GND
pin (terminal 7) and transfer case. If not, replace the
grounding wire.
Resistance of electromagnetic coil
Check the resistance between electromagnetic clutch
solenoid (terminal 8) and power GND (terminal 7). If not,
replace the electromagnetic coil.
Standard : 1.4
2.0
Allowable : 1.0 5.0