Opel Frontera UBS. Manual - part 1063

 

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Opel Frontera UBS. Manual - part 1063

 

 

4D1–14 TRANSFER CASE (STANDARD TYPE)

6. Join the rod grooves of 2WD–4WD actuator

assembly (12) and shift rod (11).

220RW030

Legend

(11) Shift Rod: 2WD–4WD (Position: 4WD)

(12) 2WD–4WD Actuator Assembly (Mode: 2WD)
(13) Rear Cover Assembly

7. Push the 2WD–4WD actuator assembly (12) with

2WD–4WD shift rod (11) till the shift rod (11) reaches
the 2WD position.

220RW031

Legend

(14) Position: 2WD
(15) Mode: 2WD

8. Tighten the 2WD–4WD actuator bolts to the specified

torque.

Torque: 19 N·m (1.9kg·m/14 lb ft)

9. Install the actuator heat protector.

10. Connect the actuator breather hose to the actuator.

11. Install the control box assembly.

Torque: 19 N·m (1.9kg·m/14 lb ft)

12. Connect the breather hoses to the control box.
13. Install the rear companion flange and front

companion flange, using the companion flange holder
5–8840–0133–0 (J–8614–11) to tighten the flange
nuts to the transfer case.

262RW067

14. Tighten the new transfer flange nuts to the specified

torque.

Torque
Rear companion flange: 167 N·m (17.0kg·m/123
lb ft)
Front companion flange: 137 N·m (14.0kg·m/101
lb ft)

15. Use the punch 5–8840–2293–0 (J–39209) to stake

the rear companion flange nut at two spots.

266RW027

TRANSFER CASE (STANDARD TYPE)

4D1–15

266RW002

16. Stake the front companion flange nut at one spot.

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

17. Install the O–ring (8) to the speedometer driven gear

bushing (7).

18. Install the driven gear to the speedometer driven gear

bushing (7).

19. Install the speedometer driven gear assembly to the

transfer rear cover.

20. Install the plate (6) to the transfer rear case and

tighten to the specified torque.

Torque: 15 N·m (1.5kg·m/11 lb ft)

21. Install the speedometer sensor and tighten to the

specified torque.

Torque: 27 N·m (2.8kg·m/20 lb ft)

225RW014

4D1–16 TRANSFER CASE (STANDARD TYPE)

Disassembly

226RW154

Legend

(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing

(5) Bearing Snap Ring
(6) Ball
(7) Speedometer Drive Gear
(8) Ball Bearing
(9) Transfer Rear Cover (with oil seal)

1. Remove the bearing snap ring (3), using a pair of snap

ring pliers.

226RS060

TRANSFER CASE (STANDARD TYPE)

4D1–17

2. Remove the rear output shaft assembly (1) from the

transfer rear cover (with oil seal).

3. Remove ball bearing (8), using a bench press and the

bearing remover 5–8840–0015–0 (J–22912–01) .

226RW186

4. Remove the speedometer drive gear (7).
5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap

ring pliers.

7. Remove the ball bearing (4) from the rear output

shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01).

226RW187

Inspection and Repair

Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.

Reassembly

1. Install transfer rear cover (with oil seal).

Oil seal replacement

D

Remove the oil seal from the transfer rear cover.

D

Apply engine oil to the oil seal outer surfaces.

D

Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.

D

Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.

220RW104

2. Set the snap ring (3), and install ball bearing (4) to the

rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).

262RW068

 

 

 

 

 

 

 

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