Opel Frontera UBS. Manual - part 190

4D2–16 TRANSFER CASE (TOD)

Transfer Case Assembly Clutch Pack and Clutch Cam

Disassembled View

266RW006

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

Disassembly

1. Remove the thrust bearing.
2. Remove the cam and coil housing.

NOTE: When the cam and coil housing is removed, the
cam balls may be detached together with the housing.  Be
careful not to lose the ball.

3. Remove the cam ball.

266RW013

4D2–17

TRANSFER CASE (TOD)

4. Remove the cam pulley.
5. Remove the wave spring.
6. Using snap ring pliers, remove the snap ring.

NOTE: Be careful not to damage the snap ring.

266RW009

7. Remove the armature plate.
8. Remove the insulator washer.
9. Remove the clutch pack assembly as a package.

266RW017

4D2–18 TRANSFER CASE (TOD)

Sprocket and Mechanical Lock

Disassembled View

266RW008

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

Disassembly

1. Remove the sprocket spacer.
2. Remove the front tone wheel.

4D2–19

TRANSFER CASE (TOD)

3. Remove the drive sprocket, lower drive sprocket, and

chain together from the front and rear output shafts.

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4. Remove the mechanical lock hub.
5. Remove the lock-up fork.
6. Remove the spring retainer from the connection

between rail shaft and lock-up fork.

7. Remove the lock-up sleeve.

261RW018

8. Remove the thrust washer.
9. Remove the magnet from the strainer set position

together with the oil pump assembly.

10. Remove the strainer from the oil pump assembly.

11. Remove the hose from the oil pump assembly.