oil OPEL FRONTERA 1998 Workshop Manual

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 . (Rr . )Rear speed sensor
reference output
2Ref . (Frt . )Front speed sensor
reference output
3SW GNDSW GND
44H SW (+)4H SW plus terminal
5Rer . (+)Rear speed sensor plus
6Frt . (+)Front speed sensor plus
7POWER GNDPower GND
8EMC (+)Electromagnetic coil
9COM (–) (Rr .)Rear speed sensor GND
10COM (–) (Frt .)Front speed sensor GND
11NCNot used
124L SW (+)4L SW plus terminal
810RW002
4H and 4L switch
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
POSITION
PIN 4 (4 to 7)
4H SWPIN 12 (3 to 12)
4L SW
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 coil
(terminal 8) and power GND (terminal 7). If not, replace
the electromagnetic coil.
Standard : 1.4
2.0
Allowable : 1.0 5.0

4D2–9 TRANSFER CASE (TOD)
Transfer Case
Disassembled View
266RW004
Legend
(1) Front Companion Flange
(2) 4H and 4L Switch, Ground Cable, and Center
Connector
(3) Offset Lever(4) Spring Pin
(5) Transfer Case Assembly
(6) Transfer Cover Assembly
(7) Rear Companion Flange
Disassembly
1. Remove the drain plug from the transfer case and
drain the oil.
2. Disconnect the 4H and 4L switch and ground cable.
3. Remove the clip fixing the harness.
4. Using the flange holder 5-8840-0133-0 (J-8614-11),
remove the flange nut, and remove front companion
flange.
5. Using the flange folder 5-8840-0133-0 (J-8614-11),
remove the flange nut, and remove rear companion
flange.
266RW005

4D2–10
TRANSFER CASE (TOD)
6. Remove the offset lever set bolt on the right side.
261RW015
7. Remove the offset lever lock spring pin.
NOTE: When removing the spring pin, note the recess
position of the pin.
261RW016
8. Remove the offset lever.
261RW017
9. Remove the sixteen bolts and detach the transfer
cover assembly from the transfer case assembly.
NOTE: When removing the transfer cover assembly, be
careful not to damage the oil seal.
Reassembly
1. Apply liquid gasket (Loctite 598 or equivalent)
uniformly to the mating face that contacts the transfer
case.
261RW023

4D2–12
TRANSFER CASE (TOD)
Transfer Cover Assembly
Disassembled View
261RW007
Legend
(1) Coil Assembly
(2) Snap Ring
(3) Ball Bearing(4) Speed Gear and Tone Wheel
(5) Ball Bearing
(6) Transfer Cover Assembly
(7) Front and Rear Speed Sensors
Disassembly
1. Using snap ring pliers, remove the snap ring.
261RW047

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

4D2–14
TRANSFER CASE (TOD)
6. Using the bearing remover 5-8840-2409-0 (J-42805)
and slide hammer 5-8840-0084-0 (J-2619-01),
remove the ball bearing for the front output shaft.
901RW234
7. Remove the bolts and front and rear speed sensors.
NOTE: Be careful not to damage the speed sensors
during the work.
261RW033
Reassembly
1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and
fill the lip with grease (Besco L2 or equivalent).
3. Using the oil seal installer 5-8840-2412-0 (J-42804),
install the oil seal to the transfer cover assembly.
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.
Dimension : 9.85 — 10.35mm (0.39 — 0.41 in)
A04RW004

4D2–15 TRANSFER CASE (TOD)
4. Apply a thin coat of grease to the seal ring of each
front and rear speed sensor, and mount the sensors
carefully.
5. Tighten the bolts to the specified torque.
Torque : 5 Nꞏm (0.5 kgꞏm/43 lb in)
NOTE: Pay attention not to mount the front (or rear)
sensor to the rear (or front) sensor position.
6. Install the ball bearing (1) for the front output shaft as
flat as shown in the figure.
261RW008
7. Mount the coil assembly and tighten the nuts to the
specified torque.
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in)
8. Connect the terminal in the central connector.
NOTE: Be careful not to damage other terminals.
9. Install speed gear and tone wheel.
10. Mount the ball bearing (2) as flat as shown in the
figure.
261RW009–1
11. Using snap ring pliers, install the snap ring to the
transfer cover assembly.NOTE: Securely install the snap ring to the groove of the
transfer cover assembly.

4D2–16
TRANSFER CASE (TOD)
Transfer Case Assembly Clutch Pack and Clutch Cam
Disassembled View
266RW006
Legend
(1) Clutch Pack Assembly
(2) Insulator Washer
(3) Armature Plate
(4) Snap Ring(5) Wave Spring
(6) Cam Pulley
(7) Cam Ball
(8) Cam and Coil Housing
(9) Thrust Bearing
Disassembly
1. Remove the thrust bearing.
2. Remove the cam and coil housing.
NOTE: When the cam and coil housing is removed, the
cam balls may be detached together with the housing. Be
careful not to lose the ball.
3. Remove the cam ball.
266RW013

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.