Opel Frontera UE. Manual - part 1368

4D2–7

TRANSFER CASE (TOD)

NOTE: When installing the oil seal, pay attention to the
direction.

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Legend

(1) Inside
(2) Outside

3. Install the companion flange.
4. Install the oil seal and washer, and using the flange

holder J–8614–11, install the new end nut to the
specified torque.

Torque: 167 N·m (123 lb ft)

5. Securely stake the end nut at one spot.

NOTE: Be sure to confirm that there is no clack at the
staked portion of the end nut after staking.

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6. Connect the rear propeller shaft assembly to the

transfer case.

Torque: 63 N·m (46 lb ft)

SECTION

4D2–8

TRANSFER CASE (TOD)

TOD Control Unit

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Legend

(1) Bracket
(2) TOD Control Unit

Removal

1. Disconnect the battery ground cable.
2. Disconnect the harness connector from the TOD

control unit.

3. Remove the bracket retaining nuts (3 pieces) and the

bracket with TOD control unit.

4. Remove the TOD control unit from the bracket.

Installation

1. Install the TOD control unit to the bracket.
2. Install the bracket with TOD control unit to the

chassis.

3. Connect the harness connector to the TOD control

unit.

4. Connect the battery ground cable.

SECTION

4D2–9

TRANSFER CASE (TOD)

Unit Repair

Disassembly and Reassembly of Major Components

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Legend

(1) Front Companion Flange, Oil Seal, Washer,

and End Nut

(2) 4H and 4L Switch
(3) Harness Assembly
(4) Harness Bracket
(5) Shift Motor Assembly
(6) Rear Companion Flange, Oil Seal, Washer and

End Nut

(7) Speedometer Sensor and Driven Gear
(8) Plate and Bracket
(9) Connector Bracket

(10) Breather Hose

(11) Transfer Case Assembly

(12) Transfer Cover Assembly

SECTION

4D2–10 TRANSFER CASE (TOD)

Disassembly

1. Remove the drain plug from the transfer case and

drain the oil.

2. Remove the speedometer sensor and driven gear.
3. Remove the front and rear speed sensor of the

harness assembly from the transfer cover assembly.

NOTE: Use care to prevent damage to speed sensor
when removing speed sensor.

4. Disconnect the clutch solenoid coil, 4H and 4L switch

harness connector.

D

Remove the harness bracket from the transfer
cover.

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5. Remove the connector bracket from the transfer

case.

D

Remove the harness assembly and shift motor
harness connector from the connector bracket.

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6. Remove the 4H and 4L switch from the transfer case.
7. Remove the shift motor assembly from the transfer

cover.

8. Using the flange holder J–8614–11, remove the end

nut.
Remove the washers, oil seals, front and rear
companion flange.

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9. Remove the transfer cover retaining bolts and the

transfer cover assembly from the transfer case
assembly.

NOTE: When removing the transfer cover assembly, use
care to prevent damage to oil seal.

10. Remove the breather hose from the transfer case.

Reassembly

1. Apply recommended liquid gasket (LOCTITE 598 or

its equivalent) uniformly to the transfer case and
cover fitting surface.

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SECTION