Opel Frontera UBS. Manual - part 2015

TRANSFER CASE (STANDARD TYPE)

4D1–29

14. Engage the 2WD–4WD sleeve with the 4WD side and

install the spring pin (3).

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15. Install the spring pin and bridge (2).
16. Install the detent ball, spring and plug and tighten the

plug (1) to the specified torque.

Torque: 25 N·m (2.5kg·m/18 lb ft)

4D1–30 TRANSFER CASE (STANDARD TYPE)

Transfer Case Assembly

Disassembled View

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Legend

(1) Transfer Case (with oil seal)
(2) Bearing Snap Ring
(3) Front Output Gear Assembly
(4) Ball Bearing
(5) Front Output Shaft
(6) Stopper Plate (Shift On The Fly model)
(7) 2WD–4WD Clutch Hub and Sleeve Assembly
(8) Block Ring (Shift On The Fly model)
(9) Outside Ring (Shift On The Fly model)

(10) Inside Ring (Shift On The Fly model)

(11) Front Output Gear

(12) Needle Bearing
(13) Sub–Gear (anti–lash plate) (M/T)
(14) Belleville Spring (M/T)
(15) Spacer (M/T)
(16) Sub–Gear Snap Ring (M/T)
(17) Bearing Collar
(18) Ball Bearing
(19) Bearing Snap Ring
(20) Snap Ring
(21) Ball Bearing

(22) Counter Gear
(23) Sub–Gear (anti–lash plate)
(24) Belleville Spring
(25) Spacer
(26) Ball Bearing
(27) Snap Ring
(28) Counter Gear Assembly
(29) Bearing Snap Ring
(30) Input Shaft Assembly
(31) Input Shaft
(32) Ball Bearing
(33) Snap Ring
(34) Plate
(35) Ball
(36) Bearing Collar
(37) Needle Bearing
(38) Transfer Input Gear
(39) High–Low Clutch Hub and Sleeve Assembly
(40) Lock Nut
(41) Ball Bearing
(42) Bearing Snap Ring

TRANSFER CASE (STANDARD TYPE)

4D1–31

Disassembly

1. Use a pair of snap ring pliers to remove the snap ring

(42).

2. Use a bearing remover 5–8840–2155–0 ( J–37217)

and puller 5–8840–2027–0 (J–37487) to remove the
ball bearing (41).

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3. Install the front companion flange temporarily.
4. Use the Companion flange holder 5–8840–0133–0

(J–8614–11) and lock nut wrench 5–8840–2156–0
(J–37219) to remove the lock nut (40).

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5. Remove the front companion flange.
6. Remove the snap ring (33) from the transfer case (1).
7. Remove the input shaft assembly (30) from the

transfer case.

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8. Use a universal puller to remove the high–low clutch

hub and sleeve (39), and transfer input gear (38).

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9. Remove needle bearing (37).

4D1–32 TRANSFER CASE (STANDARD TYPE)

10. Remove the bearing collar (36).

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11. Remove the ball (35).

12. Remove the plate (34).
13. Use a bench press and the ball bearing remover

5–8840–0015–0 (J–22912–01) to remove the ball
bearing (32) from input shaft (31).

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14. Remove the bearing snap ring (2) from the transfer

case, using a  pair of snap ring pliers.

15. Use a plastic hammer to tap the front output gear

assembly (3) free.

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16. Remove the bearing snap ring (19). Remove the ball

bearing (18) and bearing collar (17) together with
front output gear assembly: including following parts.

17. Use a bench press and the bearing remover

5–8840–0015–0 (J–22912–01) to remove the
following parts.

18. Remove the sub–gear snap ring (16), spacer (15),

belleville spring (14), and sub–gear (anti–lash plate)
(13).(M/T)

19. Remove the front output gear (11) and needle bearing

(12).

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20. Remove the inside ring (10). (Shift On The Fly model)
21. Remove the outside ring (9). (Shift On The Fly model)
22. Remove the block ring (8). (Shift On The Fly model)
23. Use a bench press and bearing remover

5–8840–0015–0 (J–22912–01) to remove the
2WD–4WD clutch hub and sleeve assembly (7) and
stopper plate (6). (Shift On The Fly model)