Opel Frontera UBS. Manual - part 184

 

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Opel Frontera UBS. Manual - part 184

 

 

4D1–38 TRANSFER CASE (STANDARD TYPE)

3. Install the sub–gear (23) to the counter gear (22).
4. Install the belleville spring (24).
5. Install the spacer (25) and put the snap ring (29) on

the sub–gear (23).

6. Install the ball bearing (26), 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

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

(27) to the counter gear (22).

226RS170

226RS021

Sub–Gear (anti–lash plate) Preload

1. Hook a length of piano wire (4) over one of the

sub–gear (5) teeth.

2. Attach the other end of the piano wire (4) to a

spring balancer.

3. Measure the sub–gear preload.

Preload : 59–98 N (6.0–10kg/13–22 lb)

226RS075

9. Install ball bearing (21), using a bench press.

10. Install snap ring (20).

11. Install the counter gear assembly (28) to the transfer

case (1).

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

(29) to the transfer case (1).

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 (4) to the

front output shaft (5).

262RS012

TRANSFER CASE (STANDARD TYPE)

4D1–39

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

assembly (7).

226RW140

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

ends away from each other. (Shift On The Fly model)

226RW141

16. Place the snap ring (2), a new stopper plate (6) (Shift

On The Fly model) and the clutch sleeve and hub
assembly (7) on the front output shaft (5).

226RW135

Legend

(6) 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 (7) together with the stopper plate
(6) (Shift On The Fly model) into place.

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

Install the block ring (8) (Shift On The Fly model) to
the clutch sleeve and hub assembly (7).

20. Install the outside ring (9) (Shift On The Fly model),

inside ring (10) (Shift On The Fly model) and needle
bearing (12) to the front output gear (11) and bearing
collar (17).

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

226RW139

4D1–40 TRANSFER CASE (STANDARD TYPE)

21. Apply engine oil to the thrust surfaces of the sub–gear

(13), the belleville spring (14), and the spacer (15).
(M/T)

262RW060

22. Install the sub–gear (anti–lash plate) (13), belleville

spring (14), and spacer (15) to the front output gear
(11).(M/T)

23. Install the sub–gear snap ring (16). (M/T)
24. Use a bench press to install the needle bearing collar

(17) together with the front output gear, aligning inside
ring claw with block ring groove.

262RS014

25. Install ball bearing (18), using a bench press.

26. Select a snap ring 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

TRANSFER CASE (STANDARD TYPE)

4D1–41

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

(19) to the output shaft (5).

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

1. Hook a length of piano wire (4) over one of the

sub–gear (5) teeth.

2. Attach the other end of the piano wire to (4) a

spring balancer.

3. Measure the sub–gear preload.

Preload: 59–98 N (6.0–10.0kg/13–22 lb)

(M/T)

226RS075

28. Install front output gear assembly (3) to the transfer

case (1).

29. Use a pair of snap ring pliers to install the snap ring (2)

to the transfer case (1).

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 (32) to the

input shaft (31).

265RS003

31. Install the plate (34), ball (35), and bearing collar (36)

and place the snap ring (33).

32. Install the needle bearing (37) and input gear (38).
33. The clutch hub face (with the heavy boss) must be

facing the transfer input gear side (7).

226RW136

34. Install the high–low clutch hub and sleeve (39), using

a bench press.

35. Install the input shaft assembly (30) to the transfer

case (1).

36. Install the snap ring (33) to the transfer case (1).

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

37. Install the front companion flange temporarily and use

the flange holder 5–8840–0133–0 (J–8614–11) and
lock nut wrench 5–8840–2156–0 (J–37219) to install
the lock nut (40).

Torque: 137 N·m (14.0kg·m/101 lb ft)

226RW190

38. Use the punch to stake the lock nut (40) at one spot.

 

 

 

 

 

 

 

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