Opel Frontera UBS. Manual - part 1080

4D2–36 TRANSFER CASE (TOD)

10. Install the reduction fork assembly together with

reduction hub to the transfer case assembly.

261RW019

11. Install the cam assembly and tighten the cam pilot

block set bolts to the specified torque.

Torque : 12 N·m (1.2 kg·m/104 lb in)

12. Tighten the detent spring to the specified torque.

Torque : 24 N·m (2.4 kg·m/17 lb in)

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13. Apply ATF to the needle bearing inside the input shaft

assembly.

14. Install the output shaft to the transfer case assembly.

4D2–37

TRANSFER CASE (TOD)

Sprocket and Mechanical Lock

Disassembled View

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Legend

(1) Strainer
(2) Hose
(3) Oil Pump Assembly
(4) Thrust Washer
(5) Mechanical Lock Hub
(6) Lock-up Sleeve

(7) Lock-up Fork
(8) Chain
(9) Lower Drive Sprocket

(10) Front Tone Wheel

(11) Drive Sprocket

(12) Sprocket Spacer

Reassembly

1. Connect the hose and strainer to the oil pump

assembly.

2. Install the oil pump assembly to the output shaft and

set the magnet to the strainer position.

3. Install the thrust washer.
4. Install the spring to the lock-up fork.

4D2–38 TRANSFER CASE (TOD)

5. Install the lock-up sleeve together with the lock-up

fork to the output shaft and lock-up shaft assembly.

6. Install the spring retainers to the lock-up fork.

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7. Install the mechanical lock hub.
8. Apply ATF to the chain.
9. Engage the chain to both sprockets.

10. Install the chain and sprocket assembly to both output

shafts.

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11. Install the front tone wheel and sprocket spacer.

4D2–39

TRANSFER CASE (TOD)

Clutch Pack and Clutch Cam

Disassembled View

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Legend

(1) Clutch Pack Assembly
(2) Insulator Washer
(3) Armature Plate
(4) Snap Ring

(5) Wave Spring
(6) Cam Pulley
(7) Cam Ball
(8) Cam and Coil Housing
(9) Thrust Bearing

Reassembly

1. Mount the clutch pack assembly to which the multi

plate disk clutch is already installed to the output
shaft.

NOTE: Mount the clutch pack assembly while adjusting
the phase of both the clutch housing and drive sprocket.

2. Install the insulator washer.
3. Install the armature plate.