Opel Frontera UE. Manual - part 109

TRANSFER CASE

4D–23

Transfer Case Assembly

Disassembled View

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Legend

(1) Bearing Snap Ring
(2) Ball Bearing
(3) Lock Nut
(4) Snap Ring (A/T)
(5) Input Shaft Assembly (A/T)
(6) High–Low Clutch Hub and Sleeve
(7) Transfer Input Gear
(8) Needle Bearing
(9) Bearing Collar

(10) Ball

(11) Plate

(12) Ball Bearing (A/T)
(13) Input Shaft (A/T)
(14) Bearing Snap Ring
(15) Front Output Gear Assembly

(16) Bearing Snap Ring
(17) Ball Bearing
(18) Bearing Collar
(19) Sub–Gear Snap Ring (M/T)
(20) Spacer (M/T)
(21) Belleville Spring (M/T)
(22) Sub–Gear (anti–lash plate) (M/T)
(23) Front Output Gear
(24) Needle Bearing
(25) Inside Ring
(26) Outside Ring
(27) Block Ring
(28) 2WD–4WD Clutch Hub and Sleeve Assembly
(29) Stopper Plate
(30) Ball Bearing
(31) Front Output Shaft

4D–24

TRANSFER CASE

(32) Bearing Snap Ring
(33) Counter Gear Assembly
(34) Snap Ring
(35) Ball Bearing
(36) Snap Ring
(37) Ball Bearing

(38) Spacer
(39) Belleville Spring
(40) Sub–Gear (anti–lash plate)
(41) Counter Gear
(42) Transfer Case (with oil seal)

Disassembly

1. Use a pair of snap ring pliers to remove the snap ring

(1).

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

5–8840–2027–0 to remove the ball bearing (2).

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3. Install the front companion flange temporarily.
4. Use the Companion flange holder 5–8840–0133–0

and lock nut wrench 5–8840–2156–0 to remove the
lock nut (3).

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5. Remove the front companion flange.
6. Remove snap ring (4). (A/T)
7. Remove the input shaft assembly (5) from the

transfer case (42). (A/T)

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8. Use the universal puller to remove the high–low

clutch hub and sleeve (6), and transfer input gear (7).

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TRANSFER CASE

4D–25

9. Remove needle bearing (8).

10. Remove bearing collar (9).

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11. Remove ball (10).

12. Remove plate (11).
13. Use a bench press and the ball bearing remover

5–8840–0015–0 to remove the ball bearing (12) from
the input shaft (13). (A/T)

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

snap ring (14).

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

assembly (15) free.

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16. Remove bearing snap ring (16).
17. Use a bench press and the bearing remover

5–8840–0015–0 to remove the following parts.

18. Remove ball bearing (17), and bearing collar (18).

Remove sub–gear snap ring (19), spacer (20),
belleville spring (21), and sub–gear (anti–lash plate)
(22). (M/T)
Remove front output gear (23) and needle bearing
(24).

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19. Remove inside ring (25).
20. Remove outside ring (26).
21. Remove block ring (27).
22. Use a bench press and bearing remover

5–8840–0015–0 to remove 2WD–4WD clutch hub
and sleeve assembly (28) and stopper plate (29).

NOTE: Do not reuse the stopper plate.

4D–26

TRANSFER CASE

23. Disassemble the 2WD–4WD clutch hub and sleeve

assembly (28).

D

Springs (1)

D

Inserts (2)

D

Clutch Hub (3)

D

Sleeve (4)

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24. Use a bench press and the ball bearing remover

5–8840–0015–0 to remove the ball bearing (30) from
front output shaft (31).

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25. Remove bearing snap ring (32).
26. Remove the counter gear assembly (33) from the

transfer case (42).

27. Use a pair of snap ring pliers to remove the snap ring

(34).

28. Use a bench press and the bearing remover

5–8840–0015–0 to remove the ball bearing (35).

29. Use a pair of snap ring pliers to remove the snap ring

(36).

30. Use a bench press and the bearing remover

5–8840–0015–0 to remove the ball bearing (37).

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31. Remove spacer (38).
32. Remove belleville spring (39).
33. Remove sub–gear (anti–lash plate) (40).
34. Remove counter gear (41).
35. Remove transfer case (with oil seal) (42), performing

the following steps  (M/T)

D

Cover the shaft splines with adhesive tape (43).

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Legend

(43) Adhesive Tape
(44) Oil Seal Lip
(45) Oil Seal Collar
(46) Bearing

D

Remove the transfer case together with
intermediate plate with gear assembly from the
transmission case (M/T).