Opel Frontera UE. Manual - part 1370

4D2–15

TRANSFER CASE (TOD)

Reassembly

Transfer cover oil seal replacement

1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and

fill the lip with grease (BESCO L2 or its equivalent).

3. Using the oil seal installer J–42804, install the oil seal

to the transfer cover assembly.

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Shift shaft oil seal replacement

4. Remove the oil seal from the transfer cover assembly.
5. Apply oil the circumference of the new oil seal.
6. Using the oil seal installer J–33951, install the oil seal

to the transfer cover assembly.
The drive in depth must be 9.4 

∼

 10.4 mm (0.370 

∼

0.409 in). The knurled end of the installer (indicated
by the arrow) must be flush with the oil seal
installation surface.

NOTE: Use care to prevent tilt to oil seal when installing
oil seal to the case.

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7. Install the ball bearing of the front output shaft to the

transfer cover.

8. Install the speed gear and tone wheel.
9. Install the ball bearing to the transfer cover.

10. Using snap ring pliers, install the snap ring to the

transfer cover.

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

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11. Install the coil assembly to the transfer cover and

tighten the set nuts (3 pieces) to the specified torque.

Torque: 10 N·m (87 lb in)

12. Install the connector to the harness terminal of the coil

assembly.

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SECTION

4D2–16 TRANSFER CASE (TOD)

Clutch Pack and Clutch Cam (Transfer Case Assembly)

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Legend

(1) Transfer Case Assembly
(2) Snap Ring
(3) Wave Spring
(4) Cam Pulley
(5) Cam Ball

(6) Cam and Coil Housing Assembly
(7) Thrust Bearing
(8) Armature Plate
(9) Insulator Washer

(10) Clutch Pack Assembly

(11) Lockup Fork Spring

Disassembly

1. Remove the lockup fork spring.
2. Remove the thrust bearing and cam and coil housing

assembly from the output shaft.

NOTE: When the cam and coil housing assembly is
removed, the cam balls may be detached together with
the housing. Pay attention not to lose the ball.

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SECTION

4D2–17

TRANSFER CASE (TOD)

3. Remove the cam ball (3 pieces).
4. Remove the cam pulley.

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5. Remove the wave spring.

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6. Using snap ring pliers, remove the snap ring.

NOTE: Use care to prevent damage to snap ring.

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7. Remove the armature plate, insulator washer and

clutch pack assembly as a package.

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SECTION

4D2–18 TRANSFER CASE (TOD)

Reassembly

1. Install the clutch pack assembly which the multi clutch

plate is orderly installed to the output shaft.

NOTE:

D

Install the clutch pack assembly while adjusting the
phase of both the clutch housing and drive sprocket.

D

During installation, the plate of the clutch pack
assembly may slide out of this fixed position (the
correct position is shown in the illustration). If this
occurs, remove all of the clutch plates of the clutch
pack assembly and reinstall them to their correct
position.

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2. Install the insulator washer and armature plate to the

clutch pack assembly.

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3. Using snap ring pliers, install the snap ring to the

output shaft.

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4. Install the wave spring to the output shaft.

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SECTION