Opel Frontera UBS. Manual - part 2010

TRANSFER CASE (STANDARD TYPE)

4D1–9

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7. Connect the rear propeller shaft to the transfer case

and tighten to the specified torque.

Torque: 63 N·m (6.4kg·m/46 lb ft)

Transfer Case Assembly

Removal

NOTE: Before removing the transmission & transfer
assembly from the vehicle, change the transfer mode to
2WD by pushing button switch on dash panel. (4WD
Switch Model)

1. Disconnect the battery ground cable.
2. Drain the transfer case fluid, if overhauling the

transter case assembly.

3. Remove the exhaust and transfer protectors.
4. Remove the rear and front propeller shafts from the

transfer case side.

5. Remove the transfer control lever knob.
6. Disconnect the harness connectors and remove the

front console.

7. Remove the selector lever assembly. Refer to

Selector Lever in the Section 7A.

8. Remove the transfer control lever.
9. Disconnect the 4WD switch connector, speed sensor

harness connector and 2WD–4WD actuator harness
connector (4WD Switch Model) from the transmission
harness.

10. Support the transfer case with a transmission jack.

11. Remove the transmission–transfer bolts and the nut

(M/T).

12. Remove the transfer case assembly from the vehicle.

4D1–10 TRANSFER CASE (STANDARD TYPE)

Installation

To install, follow the removal steps in the reverse order,
noting the following points:

1. Apply a thin coat of molybdenum disulfide grease to

the input shaft spline and install the transter case
assembly to the vehicle.

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2. Tighten the transmission–transfer bolts and the nut

(M/T) to the specified torque.

Torque: 46 N·m (4.7kg·m/34 lb ft)

3. Tighten the propeller shaft bolts to the specified

torque.

Torque: 63 N·m (6.4kg·m/46 lb ft)

4. Tighten the transfer protector bolts to the specified

torque.

Torque: 37 N·m (3.8kg·m/27 lb ft)

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TRANSFER CASE (STANDARD TYPE)

4D1–11

Transfer Rear Cover Assembly (4WD Switch Model)

Transfer Rear Cover Assembly and Associated Parts

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Legend

(1) Speedometer Sensor, Speedometer Driven

Gear and Plate

(2) Front Companion Flange
(3) Rear Companion Flange

(4) Control Box Assembly
(5) 2WD–4WD Actuator Heat Protector
(6) 2WD–4WD Actuator Assembly
(7) Transfer Rear Cover Assembly
(8) Transfer Case Assembly

4D1–12 TRANSFER CASE (STANDARD TYPE)

Removal

1. Remove the speedometer sensor.
2. Remove the plate.
3. Remove the speedometer driven gear bushing and

driven gear.

NOTE: Apply a reference mark to the driven gear bushing
before removal.

4. Remove the front companion flange and the rear

companion flange, using the flange companion holder
5–8840–0133–0 (J–8614–11) to remove the end
nuts.

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NOTE: Use a universal puller to remove the rear
companion flange.

5. Disconnect the actuator breather hose and the

transfer breather hose from the control box.

6. Remove the control box assembly.
7. Disconnect the actuator breather hose and remove

the 2WD–4WD actuator heat protector from the
2WD–4WD actuator assembly.

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8. Remove the 2WD–4WD actuator assembly bolts.
9. Pull the 2WD–4WD actuator assembly with

2WD–4WD shift rod.

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Legend

(1) Shift Rod: 2WD–4WD (Position: 2WD)
(2) 2WD–4WD Actuator Assembly
(3) Pull Cover
(4) Rear Cover Assembly
(5) Position: 4WD
(6) Mode: 2WD