Opel Frontera UBS. Manual - part 188

4D2–8

TRANSFER CASE (TOD)

Unit Repair

Inspection

Before disassembling and after assembling, check the
following items on the transfer connector terminals.

No.

NAME

CONTENTS

1

Ref . (Ref . )

Rear speed sensor refer-
ence output

2

Ref . (Frt . )

Front speed sensor refer-
ence output

3

SW GND

SW GND

4

4H SW (+)

4H SW plus terminal

5

Rer . (+)

Rear speed sensor plus

6

Frt . (+)

Front speed sensor plus

7

POWER GND

Power GND

8

SOL (+)

Electromagnetic solenoid

9

COM (–) (Ref .)

Rear speed sensor GND

10

COM (–) (Frt .)

Front speed sensor GND

11

NC

12

4L SW (+)

4L SW plus terminal

810RW002

4H and 4L switches

Check whether the 4H switch (terminals 4 and 7) and 4L
switch (terminals 12 and 3 ) work as specified in the table
below.  If yes, the continuity is established on these
switches. If not, check the switches, shift rails, transfer
case, and rear cover, and replace the failed parts.

SHIFT POSI-

TION

PIN 4 (4 to 7)

PIN 12 (3 to 12)

HIGH

OFF

OFF

(NEUTRAL)

ON

ON

4L

OFF

ON

Power GND

Check that there is a continuity between the power GND
pin (terminal 7) and transfer case.  If not, replace the
grounding wire.

Resistance of electromagnetic coil

Check the resistance between electromagnetic clutch
solenoid (terminal 8) and power GND (terminal 7).  If not,
replace the electromagnetic coil.

Standard : 1.4 

∼

 2.0

W

Allowable : 1.0 

∼

 5.0

W

4D2–9

TRANSFER CASE (TOD)

Transfer Case

Disassembled View

266RW004

Legend

(1) Front Companion Flange
(2) 4H and 4L Switch, Ground Cable, and Center

Connector

(3) Offset Lever

(4) Spring Pin
(5) Transfer Case Assembly
(6) Transfer Cover Assembly
(7) Rear Companion Flange

Disassembly

1. Remove the drain plug from the transfer case and

drain the oil.

2. Disconnect the 4H and 4L switch and ground cable.
3. Remove the clip fixing the harness.
4. Using the flange holder 5-8840-0133-0 (J-8614-11),

remove the flange nut, and remove front companion
flange.

5. Using the flange folder 5-8840-0133-0 (J-8614-11),

remove the flange nut, and remove rear companion
flange.

266RW005

4D2–10 TRANSFER CASE (TOD)

6. Remove the offset lever set bolt on the right side.

261RW015

7. Remove the offset lever lock spring pin.

NOTE: When removing the spring pin, note the recess
position of the pin.

261RW016

8. Remove the offset lever.

261RW017

9. Remove the sixteen bolts and detach the transfer

cover assembly from the transfer case assembly.

NOTE: When removing the transfer cover assembly, be
careful not to damage the oil seal.

Reassembly

1. Apply liquid gasket (Loctite 598 or equivalent)

uniformly to the mating face that contacts the transfer
case.

261RW023

4D2–11

TRANSFER CASE (TOD)

2. Tighten the sixteen bolts to the specified torque.

Torque : 31 N·m (3.2 kg·m/23 lb ft)

3. Wind the sealing tape around the drain plug thread

and tighten the plug to the specified torque.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

4. Mount the offset lever to the transfer shift and install

the spring pin.

261RW016

5. Attach the O-ring and washer to the companion

flange.

NOTE: Securely push the O-ring to the hollow of the
companion flange, and then attach the washer.

6. Use the flange holder 5-8840-0133-0 (J-8614-11) to

tighten the flange nut.

7. Tighten the flange nut to the specified torque.

Torque : 167 N·m (17.0 kg·m/123 lb ft)

8. Using the punch 5-8840-2293-0 (J-39209), securely

stake the flange nut at two spots.

NOTE: Check the staked flange nut is free from cracks.

266RW028

260RW007

9. Fix the harness with the clip.

10. Tighten the 4L and 4H switch to the specified torque.

Torque : 24 N·m (2.4 kg·m/17 lb ft)

11. Fill the transfer case with ATF II or III (1.9 liters).

12. Wind the sealing tape around the filler plug thread and

tighten the plug to the specified torque.

Torque : 25 N·m (2.5 kg·m/18 lb ft)