Opel Frontera UE. Manual - part 715

 

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Opel Frontera UE. Manual - part 715

 

 

4D–32

TRANSFER CASE

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

Tighten the transfer case bolts to the specified torque a
little at a time (M/T).

Torque : 37 N·m (3.8 kg·m/27 lb ft)

2. Apply chassis grease (51) to the sub–gear (40) and

the counter gear (41) thrust surfaces.

226RW155

3. Install sub–gear (40) to counter gear (41).
4. Install belleville spring (39).
5. Install spacer.
6. Install ball bearing, using a bench press.
7. Select a snap ring that will allow the minimum axial

play.

Clearance : 0–0.1 mm (0–0.004 in)

Snap ring availability:

Thickness

Color–coding

1.50 mm (0.059 in)

White

1.55 mm (0.061 in)

Yellow

1.60 mm (0.063 in)

Blue

226RS170

226RS021

8. Use a pair of snap ring pliers to install the snap ring

(36) to the counter gear (41).

Sub–Gear (anti–lash plate) Preload

1. Hook a length of piano wire (52) over one of the

sub–gear (53) teeth.

2. Attach the other end of the piano wire (52) to a

spring balancer.

3. Measure the sub–gear preload.

Preload : 59–98 N (6.0–10 kg/13–22 lb)

TRANSFER CASE

4D–33

226RW156

9. Install ball bearing (35), using a bench press.

10. Install snap ring (34).

11. Install the counter gear assembly (33) to the transfer

case (42).

12. Use a pair of snap ring pliers to install the snap ring

(32) to the transfer case (42).

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

13. Use a bench press to install the ball bearing (30) to the

front output shaft (31).

262RS012

14. Assemble the 2WD–4WD clutch hub and sleeve

assembly (28).

226RW140

15. Engage the springs in the same insert with the open

ends away from each other.

226RW141

4D–34

TRANSFER CASE

16. Install a new stopper plate (29) and the clutch hub and

sleeve assembly (28) to the front output shaft (31).

226RW157

Legend

(54) Front Output Gear

17. The clutch hub face (with the heavy boss) must be

facing the front output gear side.

18. Use a bench press to slowly force the clutch hub and

sleeve assembly (28) together with the stopper plate
(29) into place.

19. Align the inserts with the block ring insert grooves.

Install the block ring (27) to the clutch sleeve and hub
assembly (28).

20. Install the outside ring (26), inside ring (25) and

needle bearing (24) to the front output gear (23) and
bearing collar (18).

NOTE: Coat all parts with transmission oil before
installing them.

226RW139

21. Apply engine oil to the thrust surfaces of the

sub–gear, the belleville spring, and the spacer (M/T).

262RW014

22. Install sub–gear (anti–lash plate) (22), belleville

spring (21) and spacer (20). (M/T)

23. Install sub–gear snap ring (19). (M/T)
24. Use a bench press to install the needle bearing collar

together with the front output gear assembly, aligning
inside ring claw with block ring groove.

262RS014

TRANSFER CASE

4D–35

25. Install ball bearing (17), using a bench press.
26. Select a snap ring (16) that will allow the minimum

axial play.

Clearance : 0–0.1 mm (0–0.004 in)

Snap ring availability:

Snap ring thickness

Color coding

1.55 mm (0.061 in)

White

1.60 mm (0.063 in)

Yellow

1.65 mm (0.065 in)

Blue

1.70 mm (0.067 in)

Pink

1.75 mm (0.069 in)

Green

1.80 mm (0.071 in)

Brown

1.85 mm (0.073 in)

Red

1.90 mm (0.075 in)

Orange

262RS015

226RS021

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

(16) to the output shaft (31).

Sub-gear (anti-lash plate) preload (M/T)

1. Hook a length of piano wire (52) over one of the

sub–gear (53) teeth.

2. Attach the other end of the piano wire to (52) a

spring balancer.

3. Measure the sub–gear preload.

Preload: 59–98 N (6.0–10 kg/13–22 lb)

226RW156

28. Install front output gear assembly (15) to transfer

case (42).

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

(14) to the transfer case (42).

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

30. Use a bench press to install the ball bearing (12) to the

input shaft (13). (A/T)

265RS003

 

 

 

 

 

 

 

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