Opel Frontera UE. Manual - part 1043

MANUAL TRANSMISSION

7B–17

7. Remove the speedometer sensor(7).

Remove the plate(7).
Remove the driven gear bushing and driven gear(7).

NOTE: Apply a reference mark to the driven gear bushing
before removal.

8. Remove front companion flange(8) and rear

companion flange(9) using the flange holder
5–8840–0133–0 to remove the end nut.

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9. Disconnect breather hose from transmission and

remove gear control box assembly(10).

10. Remove 2WD–4WD actuator assembly(11) by

performing the following steps:
1. Disconnect the actuator breather hose from

2WD–4WD actuator assembly(11).

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2. Remove the 2WD–4WD actuator assembly bolts.

3. Pull the 2WD–4WD actuator assembly with

2WD–4WD shift rod.

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Legend

(1) Shift Rod: 2WD–4WD (Position: 2WD)
(2) 2WD–4WD Actuator Assembly
(3) Pull
(4) Rear Case Assembly
(5) Position: 4WD
(6) Position: 2WD

4. Offset the actuator assembly.

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7B–18

MANUAL TRANSMISSION

5. Remove the actuator assembly.

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Legend

(7) Position: 4WD
(8) Mode: 2WD

NOTE: Before removing the transmission and transfer
assembly from vehicle, change the transfer mode to 2WD
using the 4WD push button switch on dash panel.

11. Remove the transfer rear cover assembly(12) from

the transfer case(28).

12. Regarding detent, shift arm, and interlock pin(13)

disassembly, refer to Detent, Shift Arm, and Interlock
Pin in Drive Line/Axle section.

13. Use a pair of snap ring pliers to remove the bearing

snap ring(14).

14. Use a bearing remover 5–8840–2155–0 and puller

5–8840–2027–0 to remove the ball bearing(15).

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15. Install the front companion flange temporarily.

Use the flange holder 5–8840–0133–0 and lock nut
wrench 5–8840–2156–0 to remove the lock nut(16).
Remove the front companion flange.

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MANUAL TRANSMISSION

7B–19

16. Remove high-low clutch sleeve(17).

Use the universal puller to remove the high-low clutch
hub(17) and transfer input gear(18).

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17. Remove needle bearing(19), bearing collar(20),

ball(21), and plate(22).

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18. Use a pair of snap ring pliers to remove the bearing

snap ring(23).

19. Use a plastic hammer to tap the front output gear

assembly(24) free.

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20. Remove bearing snap ring(25) by using a pair of snap

ring pliers.

21. Remove the counter gear assembly(26) from the

transfer case(28).

22. Remove 1–2 and 3–4 indicator switch, pin and

ball(27).

23. Remove the transfer case assembly(28) from the

transmission case.

D

Refer to Transfer Case Assembly in Drive Line/Axle
section for repair of transfer case assembly.

24. Pull out intermediate plate with gear assembly(29)

from transmission case.

Reassembly

1. Apply recommended liquid gasket (LOCTITE 17430)

or its equivalent to the transmission case(30),
intermediate plate(29) and transfer case(28) fitting
surfaces.

2. Install the intermediate plate with gear assembly(29)

to the transmission case(30).
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or
stress.

3. Install the transfer case assembly(28) to the

intermediate plate with gear assembly.
Tighten the eight transmission-transfer case bolts to
the specified torque.

Torque: 37 N·m (3.8 kg·m/27 lb ft)

Refer to Transfer Rear Case Assembly in Drive
Line/Axle section for oil seal replacement.

4. Install 1–2 and 3–4 indicator switch, pin and ball(27)

(6VD1).

5. Install the counter gear assembly(26) to the transfer

case(28).

6. Use a pair of snap ring pliers to install the snap

ring(25) to the transfer case(28).

7B–20

MANUAL TRANSMISSION

NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.

7. Install front output gear assembly(24).
8. Use a pair of snap ring pliers to install the snap ring

(23) to the  transfer case(28).

NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.

9. Install plate(22), ball(21), bearing collar(20), needle

bearing(19), and transfer input gear(18).

10. Install High-low clutch hub and sleeve(17).

The clutch hub face (with the heavy boss) must be
facing the transfer input gear side.

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11. Install the front companion flange temporarily.

D

Use the flange holder 5–8840–0133–0 and lock nut
wrench 5–8840–2156–0 to install the lock nut(16).

Torque: 137 N·m (14.0 kg·m/101 lb ft)

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12. Use the punch to stake the lock nut at one spot.
13. Use a suitable drift and hammer to install the ball

bearing(15).

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14. Use a pair of snap ring pliers to install the bearing

snap ring(14).

15. Regarding detent, shift arm, and interlock pin(13)

assembly, refer to Detent, Shift Arm, and Interlock Pin
in Drive Line/Axle section.

16. Apply recommended liquid gasket (LOCTITE 17430)

or its equivalent to the transfer rear case fitting faces.