Opel Frontera UE. Manual - part 1372

4D2–23

TRANSFER CASE (TOD)

11. Apply ATF to the chain and engage it to both

sprockets.

12. Mount the chain and sprocket assembly to both

output shafts.

NOTE: When installing chain, the copper colored ring of
the chain (indicated by the arrow) to be installed in
direction of rear.

13. Install the front torn wheel to the front output shaft.
14. Install the spacer to the drive sprocket assembly.

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SECTION

4D2–24 TRANSFER CASE (TOD)

Transfer Case Assembly

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Legend

(1) Transfer Case (with Oil Seal)
(2) Ball Bearing
(3) Ring Gear
(4) Snap Ring
(5) Input Shaft and Carrier Assembly
(6) Snap Ring
(7) Ball Bearing

(8) Snap Ring
(9) Circular Hub

(10) Carrier Assembly

(11) Snap Ring

(12) Thrust Plate
(13) Sun Gear
(14) Input Shaft Assembly (with Bearing and

Bushing)

Disassembly

1. Using snap ring pliers, open the snap ring from the

gap on the carrier assembly.
While opening the snap ring, remove the input shaft
assembly, carrier assembly and thrust plate together
from the transfer case.

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SECTION

4D2–25

TRANSFER CASE (TOD)

2. Remove the snap ring from the transfer case.

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

265RW009

4. Using the bearing remover J–22912–01, remove the

ball bearing from the input shaft.

265R200001

5. Remove the circular hub.
6. Remove the snap ring from the carrier assembly.

265RW006

7. Remove the thrust plate from the carrier assembly.

SECTION

4D2–26 TRANSFER CASE (TOD)

8. Remove the snap ring before the ring gear.

261RW025

9. Using the ring gear remover J–42806 and a bench

press, remove the ring gear from the transfer case.

261R200005

NOTE: Removing ring gear needs a high-load press.
This means the transfer case may be damaged.
To remove and replace the ring gear, it is recommended
that the transfer case assembly should be replaced.

10. Remove the ball bearing of the front output shaft from

the transfer case.

261RY00021

Reassembly

Oil Seal Replacement

1. Remove the oil seal of the front output shaft and input

shaft from the transfer case.

2. Apply 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–42807, install the front

output shaft oil seal to the transfer case.

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SECTION