Opel Frontera UE. Manual - part 1371

4D2–19

TRANSFER CASE (TOD)

5. Install the cam pulley.
6. Place a ball on each groove of the cam pulley.

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7. Install the cam and coil housing to the output shaft.
8. Install the thrust bearing.
9. Install the lockup fork spring.

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SECTION

4D2–20 TRANSFER CASE (TOD)

Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)

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Legend

(1) Transfer Case Assembly
(2) Cam and Shaft Rail Assembly
(3) Front Output Shaft
(4) Chain
(5) Lower Drive Sprocket
(6) Front Tone Wheel
(7) Drive Sprocket
(8) Spacer
(9) Shift Fork and Rail Assembly

(10) Lockup Rail

(11) Spring Pin

(12) Shift Fork Assembly
(13) Lockup Fork
(14) Lockup Fork Spring
(15) Reduction Hub
(16) Rear Output Shaft
(17) Oil Pump Assembly (with Strainer)
(18) Thrust Washer
(19) Lockup Hub
(20) Lockup Collar Assembly
(21) Magnet

SECTION

4D2–21

TRANSFER CASE (TOD)

Disassembly

1. Remove the spacer.
2. Remove the front tone wheel, lower drive sprocket,

drive sprocket and chain together from the front and
rear output shaft.

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3. Remove the lockup collar assembly and lockup fork

together.

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4. Remove the lockup hub.
5. Remove the thrust washer.

6. Remove the magnet from the strainer set position

together with the oil pump assembly.

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7. Remove the output shaft.
8. Remove the cam and shaft rail assembly.

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9. Remove the shift fork and rail assembly, and

reduction hub.

10. Remove the spring pin from the shift fork and rail

assembly.

11. Remove the shift fork assembly from the lockup rail.

12. Remove the front output shaft from the transfer case.

SECTION

4D2–22 TRANSFER CASE (TOD)

Reassembly

1. Apply ATF to the inside of the ball bearing.
2. Install the front output shaft to the transfer case.

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3. Install the shift fork assembly to the lockup rail and fix

the assembly with the snap ring.

4. Install the shaft fork and rail assembly and reduction

hub to the transfer case.

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5. Install the output shaft to the transfer case.
6. Install the oil pump assembly to the output shaft and

attach the magnet to the strainer set position.

7. Install the thrust washer.
8. Install the lockup hub.
9. Install the cam and shaft rail assembly.

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10. Install the lockup collar assembly and lockup fork

together.

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SECTION