OPEL FRONTERA 1998 Workshop 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)

TRANSFER CASE (STANDARD TYPE)
4D1–21
5. Install the control box assembly.
Torque: 19 Nꞏm (1.9kgꞏm/14 lb ft)
6. Connect the breather hoses to the control box.
7. 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
8. Tighten the new transfer flange nuts to the specified
torque.
Torque
Rear companion flange: 167 Nꞏm (17.0kgꞏm/123
lb ft)
Front companion flange: 137 Nꞏm (14.0kgꞏm/101
lb ft)
9. Use the punch 5–8840–2293–0 (J–39209) to stake
the rear companion flange nut at two spots.
266RW027
266RW002
10. Stake the front companion flange nut at one spot.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.
11. Install the O–ring (8) to the speedometer driven gear
bushing (7).
12. Install the driven gear to the speedometer driven gear
bushing (7).
13. Install the speedometer driven gear assembly to the
transfer rear cover.
14. Install the plate (6) to the transfer rear case and
tighten to the specified torque.
Torque: 15 Nꞏm (1.5kgꞏm/11 lb ft)

4D1–22
TRANSFER CASE (STANDARD TYPE)
15. Install the speedometer sensor and tighten to the
specified torque.
Torque: 27 Nꞏm (2.8kgꞏm/20 lb ft)
225RW014

TRANSFER CASE (STANDARD TYPE)
4D1–23
Disassembly
226RW154
Legend
(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing(5) Bearing Snap Ring
(6) Ball
(7) Speedometer Drive Gear
(8) Ball Bearing
(9) Transfer Rear Cover (with oil seal)
1. Remove the bearing snap ring (3), using a pair of snap
ring pliers.
226RS060

4D1–24
TRANSFER CASE (STANDARD TYPE)
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5–8840–0015–0 (J–22912–01) .
226RW186
4. Remove the speedometer drive gear (7).
5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01).
226RW187
Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Install transfer rear cover (with oil seal).
Oil seal replacement
Remove the oil seal from the transfer rear cover.
Apply engine oil to the oil seal outer surfaces.
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.
220RW104
2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).
262RW068

TRANSFER CASE (STANDARD TYPE)
4D1–25
3. Install the bearing snap ring (5).
4. Install the ball (6).
5. Install the speedometer drive gear (7).
226RS064
6. Install ball bearing (8), using the ball bearing installer
5–8840–2159–0 (J–37223).
226RW188
7. Install the rear output shaft assembly (1) to the
transfer rear cover.
8. Install the bearing snap ring (3).
NOTE: The snap ring must be fully inserted into the
transfer rear case snap ring groove.

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)