lock OPEL FRONTERA 1998 Workshop Manual

4D2–13 TRANSFER CASE (TOD)
2. Strike the speed gear and tone wheel with a rod or
other appropriate tool from the outside of the transfer
cover assembly, and remove the ball bearing and
speed gear and tone wheel.
NOTE: Be careful not to damage the speed gear teeth.
266RW018
3. Remove the stopper plate on the back with a
precision screwdriver or other appropriate tool
starting from the small lock of the plate.
NOTE: Be careful not to damage the stopper plate during
the work.
261RW042
4. Using a terminal pull-out tool or an equivalent tool,
push down the lock to unlatch the terminal for the coil
assembly, and pull the terminal out.
NOTE: Be careful not to damage other terminals.
261RW032
5. Remove the fixing nuts of the coil assembly from the
outside of the transfer cover assembly. Remove the
coil assembly from the transfer cover.
261RW030

4D2–18
TRANSFER CASE (TOD)
Sprocket and Mechanical Lock
Disassembled View
266RW008
Legend
(1) Strainer
(2) Hose
(3) Oil Pump Assembly
(4) Thrust Washer
(5) Mechanical Lock Hub
(6) Lock-up Sleeve(7) Lock-up Fork
(8) Chain
(9) Lower Driven Sprocket
(10) Front Tone Wheel
(11) Drive Sprocket
(12) Sprocket Spacer
Disassembly
1. Remove the sprocket spacer.
2. Remove the front tone wheel.

4D2–19 TRANSFER CASE (TOD)
3.Remove the drive sprocket, lower driven sprocket,
and chain together from the front and rear output
shafts.
266RW010
4. Remove the mechanical lock hub.
5. Remove the lock-up fork.
6. Remove the spring retainers from the connection
between the rail shaft and lock-up fork.
7. Remove the lock-up sleeve.
261RW018
8. Remove the thrust washer.
9. Remove the magnet from the strainer set position
together with the oil pump assembly.
10. Remove the strainer from the oil pump assembly.
11. Remove the hose from the oil pump assembly.

4D2–20
TRANSFER CASE (TOD)
Output Shafts and Shift Control Shaft
Disassembled View
261RW010–1
Legend
(1) Transfer Case Assembly
(2) Detent Spring
(3) Front Output Shaft
(4) Reduction Hub
(5) Output Shaft
(6) Reduction Fork Assembly
(7) Lock-up Shaft
(8) Spring Pin
(9) Reduction Fork(10) Cam Assembly
(11) Snap Ring
(12) Washer
(13) Cam
(14) Cam Pilot Block
(15) Shifter Shaft Assembly
(16) Shifter Lever Shaft
(17) Snap Ring
(18) Reduction Lever Assembly
(19) Snap Ring

4D2–21 TRANSFER CASE (TOD)
Disassembly
1. Remove the output shaft.
266RW011
2. Remove the detent spring.
3. Remove the cam pilot block bolts.
4. Remove the shifter shaft assembly and cam
assembly.
5. Remove the reduction fork assembly together with
reduction hub.
261RW019
6. Remove the spring pin that fixes the reduction fork to
the lock-up shaft.
261RW020
7. Remove the reduction fork.
8. Remove the lock-up shaft.
9. Using snap ring pliers, remove the snap ring from cam
pilot block.
261RW029
10. Remove the washer.
11. Remove the cam.
12. Remove the cam pilot block.

4D2–26
TRANSFER CASE (TOD)
265RW007
Inspection and Repair
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean solvent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.
Chain
Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.
If the chain interference mark is found on the inside
w a l l o f t h e t r a n s f e r c o v e r o r t h e c h a i n i s s o s l a c k t h a t a
skipped engagement occurs between the chain and
sprocket, replace the chain.
Sprocket
Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.
Gear
Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
Thickness of Reduction Hub
Measure the thickness with a micrometer.
If the measurement exceeds the limit, replace the
reduction hub.
Standard : 3.05-3.30 mm (0.120-0.130 in)
Allowable limit : 2.5 mm (0.098 in)
265RW005
Lock-up Sleeve
Mount the mechanical lock hub, drive sprocket
assembly, and lock-up sleeve to the output shaft.
If the lock-up sleeve does not move smoothly, replace
the sleeve.
NOTE: Apply ATF to the area engaging the gear.
Thickness of Lock-up Sleeve
If the measurement exceeds the limit, replace the
lock-up sleeve.
Standard : 7.16-7.32 mm (0.282-0.288 in)
Allowable limit : 7.9 mm (0.311 in)
266RW014

4D2–27 TRANSFER CASE (TOD)
Reduction Fork
Check the reduction fork and shaft for wear, distortion,
and scratches. If defects are observed, replace the
parts.
Thickness of Reduction Fork
If the measurement exceeds the limit, replace the
reduction fork.
Standard : 3.41-3.79 mm (0.134-0.149 in)
Allowable limit : 4.4 mm (0.173 in)
261RW026
Lock-up Fork
Check the lock-up fork and shaft for wear, distortion,
and scratches. If defects are observed, replace the
parts.
Thickness Lock-up Fork
If the measurement exceeds the limit, replace the
lock-up fork.
Standard : 6.99-7.09 mm (0.275-0.279 in)
Allowable limit : 6.3 mm (0.248 in)
261RW027
Bearing
Check the profile of the needle, roller, ball, and thrust
bearings. Wash the bearings with clean solvent
completely, and dry with air.
NOTE: If the bearing is rotated excessively, the rollers
may be damaged. So, rotate the bearing slowly with your
hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
with your hand.
Use a dial indicator to measure the ball bearing play.
Allowable limit : 0.23 mm (0.009 in)
226RW143
Lock-up Fork Spring
Check the lock-up fork spring for distortion, cracking,
and wear. If defects are observed, replace the part.
Free Length of the Lock-up Fork Spring
If the measurement exceeds the limit, replace the
spring.
Standard : 60.96 mm (2.40 in)
Allowable limit : 55.0 mm (2.17 in)
220RW045

4D2–28
TRANSFER CASE (TOD)
Tension of Lock-up Fork Spring
If the measurement exceeds the limit, replace the
spring. (When compressed to 41.4 mm)
Standard : 27.1-33.8 N {2.76-3.45 kg/6.08-7.61 Ib}
Allowable limit : 24.5 N {2.5 kg/5.5 Ib}
014RW048
Tension of Detent Spring Assembly
If the measurement exceeds the limit, replace the
spring. N {kg} (When compressed by 3 mm from the
free length)
Standard : 139 N -203 {14.2-20.7 kg/31.3-45.6 Ib}
Allowable limit : 130 N {13.3 kg/29.3 Ib}
261RW041
Oil Pump
Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is
excessively worn or damaged, replace the pump.
Multi Plate Disk Clutch
If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the part or parts.
266RW003
Coil Assembly
Check the resistance of the coil with a tester. If
defects are observed, replace the assembly.
* (ordinary temperature)
Standard : 1.4
2.0
Allowable limit : 1.05.0
261RW031

4D2–34
TRANSFER CASE (TOD)
Output Shafts and Shift Control Shaft
Disassembled View
261RW010–1
Legend
(1) Transfer Case Assembly
(2) Detent Spring
(3) Front Output Shaft
(4) Reduction Hub
(5) Output Shaft
(6) Reduction Fork Assembly
(7) Lock-up Shaft
(8) Spring Pin
(9) Reduction Fork(10) Cam Assembly
(11) Snap Ring
(12) Washer
(13) Cam
(14) Cam Pilot Block
(15) Shifter Shaft Assembly
(16) Shifter Lever Shaft
(17) Snap Ring
(18) Reduction Lever Assembly
(19) Snap Ring
Reassembly
1. Apply ATF to the inside of the ball bearing for the front
output shaft.

4D2–35 TRANSFER CASE (TOD)
2. Mount the front output shaft to the transfer case.
266RW012
3. Install the shifter lever shaft to the transfer case
assembly.
4. Install the snap ring to the shifter lever shaft.
5. Install the reduction lever assembly to the shifter lever
shaft and fix the assembly with the snap ring.
261RW021
6. Install the cam to the cam pilot block.
7. Attach the washer to the cam pilot block and fix the
washer with the snap ring.
261RW029
8. Mount the reduction fork to the lock-up shaft.
9. Install the spring pin to the reduction fork and lock-up
shaft.
261RW020