4WD OPEL FRONTERA 1998 Repair Manual

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).

4D1–28
TRANSFER CASE (STANDARD TYPE)
Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Place the shift block (15) in the transfer case (16).
2. Set the shift arm (14) on the High–Low sleeve.
3. Push the High–Low shift rod (13) through the shift
arm (14) and block (14).
4. Engage the High–Low sleeve with the 4H (1) side.
5. Install the spring pins (12) to the shift block (15) and
shift arm (14).
262RW012
6 . I n s t a l l t h e s e l e c t r o d a s s e m b l y ( 11 ) , j o i n i n g i t s l e v e r t o
the shift block groove.
7. Engage the High–Low sleeve with the 4H side and
install the the interlock pin (9) and spring (10) in the
proper direction.
8. Place the 2WD–4WD shift block (7) in the transfer
case (16).
9. Set the 2WD–4WD shift arm (6) on the 2WD–4WD
sleeve.
10. Push the 2WD–4WD shift rod (5) through the
2WD–4WD shift arm (6) and 2WD–4WD shift block
(7).
11. Install the 2WD–4WD shift rod (5) with the interlock
pin pushed in.
262RW035
Legend
(18) 2WD–4WD
(19) 4H Side
(20) Interlock pin
(21) 2WD
(22) 4WD
(23) Rod: 2–4
(24) Rod: H–L
(25) 4H
(26) 4L
(27) 4
2
(28) 4
4
12. Install the 4WD indicator switch and gasket (8).
Tighten to the specified torque.
Torque: 39 Nꞏm (4.0kgꞏm/29 lb ft)
13. Install the spring (4).

TRANSFER CASE (STANDARD TYPE)
4D1–29
14. Engage the 2WD–4WD sleeve with the 4WD side and
install the spring pin (3).
262RW022
15. Install the spring pin and bridge (2).
16. Install the detent ball, spring and plug and tighten the
plug (1) to the specified torque.
Torque: 25 Nꞏm (2.5kgꞏm/18 lb ft)

4D1–30
TRANSFER CASE (STANDARD TYPE)
Transfer Case Assembly
Disassembled View
226RW132
Legend
(1) Transfer Case (with oil seal)
(2) Bearing Snap Ring
(3) Front Output Gear Assembly
(4) Ball Bearing
(5) Front Output Shaft
(6) Stopper Plate (Shift On The Fly model)
(7) 2WD–4WD Clutch Hub and Sleeve Assembly
(8) Block Ring (Shift On The Fly model)
(9) Outside Ring (Shift On The Fly model)
(10) Inside Ring (Shift On The Fly model)
(11) Front Output Gear
(12) Needle Bearing
(13) Sub–Gear (anti–lash plate) (M/T)
(14) Belleville Spring (M/T)
(15) Spacer (M/T)
(16) Sub–Gear Snap Ring (M/T)
(17) Bearing Collar
(18) Ball Bearing
(19) Bearing Snap Ring
(20) Snap Ring
(21) Ball Bearing(22) Counter Gear
(23) Sub–Gear (anti–lash plate)
(24) Belleville Spring
(25) Spacer
(26) Ball Bearing
(27) Snap Ring
(28) Counter Gear Assembly
(29) Bearing Snap Ring
(30) Input Shaft Assembly
(31) Input Shaft
(32) Ball Bearing
(33) Snap Ring
(34) Plate
(35) Ball
(36) Bearing Collar
(37) Needle Bearing
(38) Transfer Input Gear
(39) High–Low Clutch Hub and Sleeve Assembly
(40) Lock Nut
(41) Ball Bearing
(42) Bearing Snap Ring

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
5–8840–0015–0 (J–22912–01) to remove the ball
bearing (32) from input shaft (31).
265RW013
14. Remove the bearing snap ring (2) from the transfer
case, using a pair of snap ring pliers.15. Use a plastic hammer to tap the front output gear
assembly (3) free.
262RS009
16. Remove the bearing snap ring (19). Remove the ball
bearing (18) and bearing collar (17) together with
front output gear assembly: including following parts.
17. Use a bench press and the bearing remover
5–8840–0015–0 (J–22912–01) to remove the
following parts.
18. Remove the sub–gear snap ring (16), spacer (15),
belleville spring (14), and sub–gear (anti–lash plate)
(13).(M/T)
19. Remove the front output gear (11) and needle bearing
(12).
262RW070
20. Remove the inside ring (10). (Shift On The Fly model)
2 1 . R e m o v e t h e o u t s i d e r i n g ( 9 ) . ( S h i f t O n T h e F l y m o d e l )
22. Remove the block ring (8). (Shift On The Fly model)
23. Use a bench press and bearing remover
5–8840–0015–0 (J–22912–01) to remove the
2WD–4WD clutch hub and sleeve assembly (7) and
stopper plate (6). (Shift On The Fly model)

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 model)
Inserts (2) (Shift On The Fly model)
Clutch Hub (3)
Sleeve (4)
226RW133
25. Use a bench press and the ball bearing remover
5–8840–0015–0 (J–22912–01) to remove the ball
bearing (4) from front output shaft (5).
262RW071
26. Remove bearing snap ring (29) from transfer case.
27. Remove the counter gear assembly (28) from the
transfer case (1).
28. Use a pair of snap ring pliers to remove the snap ring
(20).29. Use a bench press and the bearing remover
5–8840–0015–0 (J–22912–01) to remove the ball
bearing (21).
30. Use a pair of snap ring pliers to remove the snap ring
(27).
31. Use a bench press and the bearing remover
5–8840–0015–0 (J–22912–01) to remove the ball
bearing (26).
226RW191
32. Remove the spacer (25).
33. Remove the belleville spring (24).
34. Remove the sub–gear (anti–lash plate) (23) from the
counter gear (22).
Inspection and Repair
1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and
channel in each case half to remove any obstructions
or cleaning solvent residue.
Gears
1. Inspect all the gear teeth for signs of excessive wear
or damage and check all the gear splines for burrs,
nicks, wear or damage. Remove the minor nicks or
scratches on an oil stone. Replace any part exhibiting
excessive wear or damage.
Front Output Gear Inside Diameter
1. Use an inside dial indicator to measure the gear inside
diameter.

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 block ring and the dog teeth.
2. If the measured value exceeds the specified limit, the
2WD–4WD synchronizer assembly must be
replaced.
Block ring and insert clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 mm (0.031 in)
226RW142
Clutch Hub and Insert Clearance
1. Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
2. If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard : 0.01–0.19 mm (0.0004–0.0075 in)
Limit : 0.3 mm (0.012 in)
226RS038
Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.

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