Opel Frontera UE. Manual - part 108

TRANSFER CASE

4D–19

Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)

Disassembled View

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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

4D–20

TRANSFER CASE

Disassembly

1. Remove detent ball, spring and plug (1).
2. Use a spring pin remover to remove the spring pin (2)

from the bridge (2).

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3. Remove spring (4).
4. Engage the 2WD–4WD sleeve with front output gear.

Remove the spring pin (3) from the block (7). Remove
the shift rod (5).

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5. Remove shift arm (6).
6. Remove shift block (7).
7. Remove 4WD indicator switch (8).
8. Use a magnetic tool to remove the interlock pin (9)

and spring (10) from the transfer case (16).

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9. Remove select rod assembly (11).

10. Use a spring pin remover to remove the shift arm

spring pin (12) from the shift arm (14) and shift block
(15). Remove the high–low shift rod (13) from transfer
case (16).

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11. Remove shift arm (14).

12. Remove shift block (15) from transfer case (16).

TRANSFER CASE

4D–21

Inspection and Repair

Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.

Reassembly

1. Place shift block (15) in transfer case (16).
2. Set shift arm (14) on the High–Low sleeve.
3. Push High–Low shift rod (13) through shift arm (14)

and block (15).

4. Engage the High–Low sleeve with the 4H (1) side.
5. Install the spring pin (12) to the shift block (15) and

shift arm (14).

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6. Install select rod assembly (11), joining its lever to

shift block (15) groove.

7. Engage the High–Low sleeve with the 4H side and

install the interlock pin (9) and spring (10) in the
proper direction.

8. Place 2WD–4WD shift block (7) in the transfer case

(16).

9. Set 2WD–4WD shift arm (6) on the 2WD–4WD

sleeve.

10. Puh 2WD–4WD shift rod (5) through 2WD–4WD shift

arm (6) and 2WD–4WD shift block (7).

11. Install the 2WD–4WD shift rod (5) with interlock pin

pushed in.

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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

4D–22

TRANSFER CASE

12. Install 4WD indicator switch and gasket (8).

Tighten to the specified torque.

Torque: 39 N·m (4.0 kg·m/29 lb ft)

13. Install spring (4).
14. Engage the 2WD–4WD sleeve with the 4WD side and

install the spring pin (3).

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15. Install spring pin (2) and bridge (2).
16. Install detent ball, spring and plug and tighten the plug

to the specified torque.

Torque: 25 N·m (2.5 kg·m/18 lb ft)