Opel Frontera UBS. Manual - part 186

4D1–46 TRANSFER CASE (STANDARD TYPE)

Special Tools

ILLUSTRATION

PART NO.

PART NAME

5–8840–0015–0

(J–22912–01)

Bearing

remover/installer

5–8840–2279–0

(J–38592)

Transfer case oil seal

installer

5–8840–2156–0

(J–37219)

Mainshaft nut wrench

5–8840–2159–0

(J–37223)

Rear output shaft and

bearing installer

5–8840–2293–0

(J–39209)

Punch, end nut

5–8840–2281–0

(J–38594)

Front output shaft oil

seal installer

ILLUSTRATION

PART NO.

PART NAME

5–8840–2292–0

(J–39208)

Rear oil seal installer

5–8840–2192–1

(J–37486–A)

Bearing installer adapter

5–8840–0133–0

(J–8614–11)

Flange holder

5–8840–2155–0

(J–37217)

Mainshaft end bearing

remover

5–8840–2027–0

(J–37487)

Puller

5–8840–0007–0

(J–8092)

Driver handle

4D2–1

TRANSFER CASE (TOD)

DRIVELINE/AXLE

TRANSFER CASE (TOD)

CONTENTS

Service Precaution

4D2–1

. . . . . . . . . . . . . . . . . . . . . . 

Transfer Case Assembly

4D2–2

. . . . . . . . . . . . . . . . . 

Removal

4D2–2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

4D2–3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Rear Oil Seal

4D2–5

. . . . . . . . . . . . . . . . . . . 

Transfer Rear Oil Seal and Associated
 Parts

4D2–5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Removal

4D2–5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

4D2–5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

TOD ECU

4D2–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Removal

4D2–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

4D2–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Unit Repair

4D2–8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection

4D2–8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Case

4D2–9

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembled View

4D2–9

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–9

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–10

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Cover Assembly

4D2–12

. . . . . . . . . . . . . . . . 

Disassembled View

4D2–12

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–12

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–14

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Case Assembly Clutch Pack and
 Clutch Cam

4D2–16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembled View

4D2–16

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–16

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Sprocket and Mechanical Lock

4D2–18

. . . . . . . . . . . . 

Disassembled View

4D2–18

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–18

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Output Shafts and Shift Control Shaft

4D2–20

. . . . . . 

Disassembled View

4D2–20

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–21

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Case

4D2–23

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembled View

4D2–23

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–24

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

4D2–26

. . . . . . . . . . . . . . . . . . 

Transfer Case

4D2–30

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembled View

4D2–30

. . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–30

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Output Shafts and Shift Control Shaft

4D2–34

. . . . . . 

Disassembled View

4D2–34

. . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–34

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Sprocket and Mechanical Lock

4D2–37

. . . . . . . . . . . . 

Disassembled View

4D2–37

. . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–37

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Clutch Pack and Clutch Cam

4D2–39

. . . . . . . . . . . . . 

Disassembled View

4D2–39

. . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–39

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Main Data and Specifications

4D2–41

. . . . . . . . . . . . . 

Special Tools

4D2–43

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

Service Precaution

WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

SECTION

4D2–2

TRANSFER CASE (TOD)

Transfer Case Assembly

Removal

F07RW083

Legend

(1) Front Propeller Shaft
(2) Front Console
(3) Transfer Control Lever
(4) Selector Lever Assembly
(5) Transfer Connector
(6) Wiring Harness Connector

(7) Exhaust Pipe
(8) Rear Propeller Shaft
(9) Seat Belt Tension Rod

(10) Transfer Case Bolt

(11) Transfer Protector

(12) Breather Hose
(13) Transfer Case

1. Disconnect the ground cable.
2. Remove the transfer protector.
3. Remove the rear propeller shaft from the transfer

case.

4. Remove the front propeller shaft from the transfer

case.

5. Remove the shift control rod from the select lever

assembly.

4D2–3

TRANSFER CASE (TOD)

6. Disconnect the wiring harness connector and shift

lock cable and then remove the front console.

7. Remove the selector lever assembly and put it aside.
8. Remove the transfer control lever.
9. Disconnect the breather hose.

10. Remove the left front exhaust pipe fixing bolts and

nuts, and put the exhaust pipe aside.

11. Remove the left seat belt tension rod and put the rear

proper shaft aside.

260RW006

12. Remove the silencer.
13. Disconnect the transfer connector from the top of the

transfer case.

14. Disconnect the speed sensor harness connector.
15. Remove the fuel pipe clip fixing bolt on the transfer

case.

16. Support the transmission with a jack.
17. Remove the seven bolts from the transfer case.
18. Remove transfer case assembly.

Installation

To install, follow the removal steps in the reverse order,
nothing the following points:

1. Apply a thin coat of grease (Besco L2) or equivalent to

the input shaft spline.

261RW024

2. Mount the transfer case.