4WD OPEL FRONTERA 1998 Service Manual

4D1–4
TRANSFER CASE (STANDARD TYPE)
M/T, WO/Shift On The Fly, WO/4WD Switch, model
A07RW053

TRANSFER CASE (STANDARD TYPE)
4D1–5
A/T, W/Shift On The Fly, W/4WD Switch, model
A07RW001

4D1–6
TRANSFER CASE (STANDARD TYPE)
A/T, W/Shift On The Fly, WO/4WD Switch, model
A07RW056

TRANSFER CASE (STANDARD TYPE)
4D1–7
A/T, WO/Shift On The Fly, WO/4WD Switch, model
A07RW055
The transfer case is used to provide a means of providing
power flow to the front axle. The transfer case also
provides a means of disconnecting the front axle,
providing better fuel economy and quieter operation when
the vehicle is driven on improved roads where four wheel
drive is not required. In addition, the transfer case
provides an additional gear reduction when placed in low
range, which is useful when difficult off–road conditions
are encountered.
A floor mounted shift lever is used to select the high–low
range. When four wheel drive switch has been turned on,
the four wheel drive indicator light is designed to come on
when the front axle has been engaged.

TRANSFER CASE (STANDARD TYPE)
4D1–9
266RW002
7. Connect the rear propeller shaft to the transfer case
and tighten to the specified torque.
Torque: 63 Nꞏm (6.4kgꞏm/46 lb ft)
Transfer Case Assembly
Removal
NOTE: Before removing the transmission & transfer
assembly from the vehicle, change the transfer mode to
2WD by pushing button switch on dash panel. (4WD
Switch Model)
1. Disconnect the battery ground cable.
2. Drain the transfer case fluid, if overhauling the
transter case assembly.
3. Remove the exhaust and transfer protectors.
4. Remove the rear and front propeller shafts from the
transfer case side.
5. Remove the transfer control lever knob.
6. Disconnect the harness connectors and remove the
front console.
7. Remove the selector lever assembly. Refer to
Selector Lever in the Section 7A.
8. Remove the transfer control lever.
9. Disconnect the 4WD switch connector, speed sensor
harness connector and 2WD–4WD actuator harness
connector (4WD Switch Model) from the transmission
harness.10. Support the transfer case with a transmission jack.
11. Remove the transmission–transfer bolts and the nut
(M/T).
12. Remove the transfer case assembly from the vehicle.

TRANSFER CASE (STANDARD TYPE)
4D1–11
Transfer Rear Cover Assembly (4WD Switch Model)
Transfer Rear Cover Assembly and Associated Parts
220RW102
Legend
(1) Speedometer Sensor, Speedometer Driven
Gear and Plate
(2) Front Companion Flange
(3) Rear Companion Flange(4) Control Box Assembly
(5) 2WD–4WD Actuator Heat Protector
(6) 2WD–4WD Actuator Assembly
(7) Transfer Rear Cover Assembly
(8) Transfer Case Assembly

4D1–12
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 actuator breather hose and the
transfer breather hose from the control box.
6. Remove the control box assembly.
7. Disconnect the actuator breather hose and remove
the 2WD–4WD actuator heat protector from the
2WD–4WD actuator assembly.
220RW085
8. Remove the 2WD–4WD actuator assembly bolts.
9. Pull the 2WD–4WD actuator assembly with
2WD–4WD shift rod.
220RW027
Legend
(1) Shift Rod: 2WD–4WD (Position: 2WD)
(2) 2WD–4WD Actuator Assembly
(3) Pull Cover
(4) Rear Cover Assembly
(5) Position: 4WD
(6) Mode: 2WD

TRANSFER CASE (STANDARD TYPE)
4D1–13
10. Offset the actuator assembly.
220RW028
11. Remove the actuator assembly.
220RW029
Legend
(7) Position: 4WD
(8) Mode: 2WD
12. 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. 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)
5. Shift the 2WD–4WD shift rod (11) to the 4WD side.

4D1–14
TRANSFER CASE (STANDARD TYPE)
6. Join the rod grooves of 2WD–4WD actuator
assembly (12) and shift rod (11).
220RW030
Legend
(11) Shift Rod: 2WD–4WD (Position: 4WD)
(12) 2WD–4WD Actuator Assembly (Mode: 2WD)
(13) Rear Cover Assembly
7. Push the 2WD–4WD actuator assembly (12) with
2WD–4WD shift rod (11) till the shift rod (11) reaches
the 2WD position.
220RW031
Legend
(14) Position: 2WD
(15) Mode: 2WD
8. Tighten the 2WD–4WD actuator bolts to the specified
torque.
Torque: 19 Nꞏm (1.9kgꞏm/14 lb ft)
9. Install the actuator heat protector.
10. Connect the actuator breather hose to the actuator.11. Install the control box assembly.
Torque: 19 Nꞏm (1.9kgꞏm/14 lb ft)
12. Connect the breather hoses to the control box.
13. Install the rear companion flange and front
companion flange, using the companion flange holder
5–8840–0133–0 (J–8614–11) to tighten the flange
nuts to the transfer case.
262RW067
14. Tighten the new transfer flange nuts to the specified
torque.
To r q u e
Rear companion flange: 167 Nꞏm (17.0kgꞏm/123
lb ft)
Front companion flange: 137 Nꞏm (14.0kgꞏm/101
lb ft)
15. Use the punch 5–8840–2293–0 (J–39209) to stake
the rear companion flange nut at two spots.
266RW027

TRANSFER CASE (STANDARD TYPE)
4D1–19
Transfer Rear Cover Assembly (Except 4WD Switch Model)
Transfer Rear Cover Assembly and Associated Parts
220RW116
Legend
(1) Speedometer Sensor, Speedometer Driven
Gear and Plate
(2) Front Companion Flange(3) Rear Companion Flange
(4) Control Box Assembly
(5) Transfer Rear Cover Assembly
(6) Transfer Case Assembly