clutch OPEL FRONTERA 1998 Owner's Guide

4B2–47 DRIVE LINE CONTROL SYSTEM (TOD)
StepActionYe sNo
11. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
Is the continuity established between terminals (B–67)4 and
(B–67)12?
Go to Step 2Go to Step 4
21. Connect the ECU connector.
2. Start the engine.
3. Set the TOD mode.
Does the voltage between terminals 4 and 20 indicate at least
0.4V?
Go to Step 3
The ECU has
failed. Replace
the ECU.
Go to Step 5
3Is the battery voltage always observed between terminals 4 and
20?
The harness is
short–circuited on
the battery.
Repair the circuit.
Go to Step 5
The phenomenon
is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
Go to Step 5
41. Disconnect the M–27 connector.
Is the continuity established between transfer connector
terminals (A–3)8 and (A–3)7?
The harness is
broken. Repair
the circuit.
Go to Step 5
Replace the
transfer
electromagnetic
coil (solenoid
clutch).
Go to Step 5
51. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
Repeat the
“Diagnosis Flow”.
Return to Step 5

4B2–91 DRIVE LINE CONTROL SYSTEM (TOD)
StepActionYe sNo
1Is the trouble code 31 or 26 recorded?Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 7
Go to Step 2
2Is any of the trouble codes 28, 32 and 33 recorded?Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 7
Go to Step 3
3When the transfer lever is in the specified position, do the TOD
indicator lamps show the correct status?
Go to Step 4
Examine the
trouble based on
“Trouble
Diagnosis
Depending on
The Status of
TOD Indicator”.
Go to Step 7
4Shift the transfer lever to the 4L position, fully turn the steering to
the left (or right) end, and start the creep run. Does the tight
corner braking occur?
Go to Step 5
Repair the
transfer
assembly.
Go to Step 7
51. Shift the transfer lever to the high (TOD) position.
2. Turn on the starter switch.
Does the voltage between terminals 4 and 20 indicate at least
0.1V while the throttle is completely open?
Go to Step 6
The ECU has
failed. Replace
the ECU.
Go to Step 7
6Does the voltage between terminals 4 and 20 indicate at least 3V
while the throttle is completely closed?The TOD clutch
is worn. Repair
the transfer
assembly.
Go to Step 7
The ECU has
failed. Replace
the ECU.
Go to Step 7
7Check that all the parts are mounted.
Is this step complete?Repeat the
“Diagnosis Flow”.
Return to Step 7

4C–14
DRIVE SHAFT SYSTEM
Front Hub and Disc with Manual Locking Hub
Disassembled View
411RW009
Legend
(1) Bolt
(2) Cover Assembly
(3) Gasket
(4) Knob
(5) X–ring
(6) Detent Ball and Spring
(7) Snap Ring
(8) Clutch Assembly
(9) Compression Spring
(10) Follower
(11) Retaining Spring
(12) Snap Ring and Shim(13) Body Assembly
(14) Inner Assembly
(15) Spacer
(16) Ring
(17) Snap Ring
(18) Snap Ring
(19) Lock Washer and Lock Screw
(20) Hub Nut
(21) Hub and Disc Assembly
(22) Outer Bearing Outer Race
(23) ABS Sensor Ring (if so equipped)
(24) Inner Bearing Outer Race
(25) Oil Seal
Disassembly
1. Before disassembly, jack up the front of vehicle and
support frame with jack stands.2. Remove the disc brake caliper assembly and hang it
on the frame with wires. Refer to Front Disk Brake
Caliper Assembly in Brakes section.

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–28
DRIVE SHAFT SYSTEM
Shift On The Fly System
Shift On The Fly System and Associated Parts
412RW004
Legend
(1) Filler Plug
(2) Bolt
(3) Oil Seal
(4) Snap Ring(External)
(5) Inner Shaft Bearing
(6) Snap Ring(Internal)
(7) Inner Shaft(8) Needle Bearing
(9) Clutch Gear
(10) Sleeve
(11) Housing
(12) Front Axle Drive Shaft (LH side)with Bracket
(13) Bolt
(14) Actuator Assembly
(15) Bolt
Disassembly
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove
front axle drive shaft from front axle case.3. Remove Actuator Assembly and draw out actuator
ASM.
4. Remove housing.
5. Remove sleeve.
6. Remove clutch gear.

4C–30
DRIVE SHAFT SYSTEM
Inspection and Repair
Inspect the removed parts. If there are abnormalities
such as wear and damage, take corrective action or
replace.
Visual Check
1. Check and see if the inner shaft has any
abnormalities such as wear and damage.
412RW014
2. When inspecting the inner shaft, be sure to check and
see if its splined part is twisted, worn, or cracked. If so,
replace with a new shaft. In case of an abnormality in
its gear part (a slide with sleeve), replace the shaft.
420RS008
Inner Shaft Run–Out
With both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.
Limit: 0.5 mm (0.02 in)max.
NOTE: Do not heat the shaft to correct its bend.
412RS026
Inner Shaft Bearing
412RW006
Legend
(1) Inner Shaft Bearing
(2) Inner Shaft
(3) Clutch Gear
1. Inspect the state of inner shaft bearing. If any
abnormality such as roughness is found, replace with
a new inner shaft bearing.
2. Insert a clutch gear and check the state of needle
bearing.
3. If there is an abnormality such as roughness, replace
the needle bearing.

4C–31 DRIVE SHAFT SYSTEM
Sleeve Condition
Check and see that there is no wear, damage, or cracking
in the sleeve.
NOTE: Close inspection of the groove and inner gear are
required because those are important parts.
Sleeve Function
412RW011Operate the sleeve with the inner shaft combined with the
clutch gear. If roughness is felt, replace the sleeve.
NOTE: Gear oil should be applied to the contact surface
of gear.
Check the width of sleeve center groove.
Limit: 7.1 mm (0.28 in) max.
412RW022
Clutch Gear Condition
Check and see that there is no wear, damage, cracking,
or any other abnormality in the clutch gear.
Clutch Gear Function
412RW010If there is an abnormality such as roughness when
operated in combination with sleeve, replace the clutch
gear.
NOTE: When inspecting, gear oil should be applied to the
contact surface of gear.
Clutch Gear Journal Diameter
Make sure of the size illustrated.
Limit: 36.98 mm (1.456 in) min.
412RW009

4C–34
DRIVE SHAFT SYSTEM
NOTE: Be careful not to damage seal.
6. Install snap ring (internal) in the groove of front axle
case.
NOTE: Be sure to install the snap ring properly.
412RW017
7. Apply differential gear oil to clutch gear, then install
clutch gear.
8. Apply differential gear oil to sleeve, then install
sleeve.
9. Clean contact surface with the front axle and actuator
mounting surface. Apply liquid gasket to the contact
surface on the front axle case, then install in the
housing.
412RW023
10. Tighten bolts to specified torque.
Torque: 116Nꞏm (11.8 kgꞏm/85 lb ft)11. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
Torque: 39Nꞏm (4.0 kgꞏm/29 lb ft)
12. Apply liquid gasket to the contact surface on the
actuator side.
412RW012
13. Align shift arm with the groove of sleeve and install the
actuator.
14. Tighten bolts to specified torque.
Torque: 13Nꞏm (1.3 kgꞏm/113 lb in)
15. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
Torque: 116Nꞏm (11.8 kgꞏm/85 lb ft)
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.4lit (1.23 Imp qt/1.48 US qt)
Actuator Housing
Oil Capacity: 0.12lit (0.10 Imp qt/0.13 US qt)
17. Install filler plug through gasket and tighten to
specified torque.
To r q u e : 7 8 N ꞏm ( 5 8 l b f t )