Opel Frontera UBS. Manual - part 2011

TRANSFER CASE (STANDARD TYPE)

4D1–13

10. Offset the actuator assembly.

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11. Remove the actuator assembly.

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Legend

(7) Position: 4WD
(8) Mode: 2WD

12. Remove the transfer rear cover assembly from the

transfer case assembly.

Installation

1. Apply the recommended liquid gasket (LOCTITE

17430) or its equivalent to the transfer rear cover
fitting faces.

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2. Install the transfer rear cover assembly to the transfer

case assembly.

3. Perform the following steps before fitting the transfer

rear case:
1. Shift the high–low shift rod to the 4H side.

2. The cut–away portion of the select rod head (9)

should align with that of the rear case hole’s
stopper (10).

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4. Tighten the transfer rear case bolts to the specified

torque.

Torque: 37 N·m (3.8kg·m/27 lb ft)

5. Shift the 2WD–4WD shift rod (11) to the 4WD side.

4D1–14 TRANSFER CASE (STANDARD TYPE)

6. Join the rod grooves of 2WD–4WD actuator

assembly (12) and shift rod (11).

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Legend

(11) Shift Rod: 2WD–4WD (Position: 4WD)

(12) 2WD–4WD Actuator Assembly (Mode: 2WD)
(13) Rear Cover Assembly

7. Push the 2WD–4WD actuator assembly (12) with

2WD–4WD shift rod (11) till the shift rod (11) reaches
the 2WD position.

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Legend

(14) Position: 2WD
(15) Mode: 2WD

8. Tighten the 2WD–4WD actuator bolts to the specified

torque.

Torque: 19 N·m (1.9kg·m/14 lb ft)

9. Install the actuator heat protector.

10. Connect the actuator breather hose to the actuator.

11. Install the control box assembly.

Torque: 19 N·m (1.9kg·m/14 lb ft)

12. Connect the breather hoses to the control box.
13. Install the rear companion flange and front

companion flange, using the companion flange holder
5–8840–0133–0 (J–8614–11) to tighten the flange
nuts to the transfer case.

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14. Tighten the new transfer flange nuts to the specified

torque.

Torque
Rear companion flange: 167 N·m (17.0kg·m/123
lb ft)
Front companion flange: 137 N·m (14.0kg·m/101
lb ft)

15. Use the punch 5–8840–2293–0 (J–39209) to stake

the rear companion flange nut at two spots.

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TRANSFER CASE (STANDARD TYPE)

4D1–15

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16. Stake the front companion flange nut at one spot.

NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.

17. Install the O–ring (8) to the speedometer driven gear

bushing (7).

18. Install the driven gear to the speedometer driven gear

bushing (7).

19. Install the speedometer driven gear assembly to the

transfer rear cover.

20. Install the plate (6) to the transfer rear case and

tighten to the specified torque.

Torque: 15 N·m (1.5kg·m/11 lb ft)

21. Install the speedometer sensor and tighten to the

specified torque.

Torque: 27 N·m (2.8kg·m/20 lb ft)

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4D1–16 TRANSFER CASE (STANDARD TYPE)

Disassembly

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Legend

(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing

(5) Bearing Snap Ring
(6) Ball
(7) Speedometer Drive Gear
(8) Ball Bearing
(9) Transfer Rear Cover (with oil seal)

1. Remove the bearing snap ring (3), using a pair of snap

ring pliers.

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