Opel Frontera UBS. Manual - part 2016

TRANSFER CASE (STANDARD TYPE)

4D1–33

NOTE: Do not reuse the stopper plate. (Shift On The Fly
model)

24. Disassemble the 2WD–4WD clutch hub and sleeve

assembly.

D

Springs (1) (Shift On The Fly model)

D

Inserts (2) (Shift On The Fly model)

D

Clutch Hub (3)

D

Sleeve (4)

226RW133

25. Use a bench press and the ball bearing remover

5–8840–0015–0 (J–22912–01) to remove the ball
bearing (4) from front output shaft (5).

262RW071

26. Remove bearing snap ring (29) from transfer case.
27. Remove the counter gear assembly (28) from the

transfer case (1).

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

(20).

29. Use a bench press and the bearing remover

5–8840–0015–0 (J–22912–01) to remove the ball
bearing (21).

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

(27).

31. Use a bench press and the bearing remover

5–8840–0015–0 (J–22912–01) to remove the ball
bearing (26).

226RW191

32. Remove the spacer (25).
33. Remove the belleville spring (24).
34. Remove the sub–gear (anti–lash plate) (23) from the

counter gear (22).

Inspection and Repair

1. Make the necessary repair or parts replacement if

wear, damage or any other abnormal conditions are
found during inspection.

2. Wash all parts thoroughly in clean solvent. Be sure all

old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and
channel in each case half to remove any obstructions
or cleaning solvent residue.

Gears

1. Inspect all the gear teeth for signs of excessive wear

or damage and check all the gear splines for burrs,
nicks, wear or damage. Remove the minor nicks or
scratches on an oil stone. Replace any part exhibiting
excessive wear or damage.

Front Output Gear Inside Diameter

1. Use an inside dial indicator to measure the gear inside

diameter.

4D1–34 TRANSFER CASE (STANDARD TYPE)

2. If the measured value exceeds the specified limit, the

gear must be replaced.

Gear inside diameter

Standard : 48.000–48.013 mm (1.8898–1.8903 in)

Limit : 48.10 mm (1.894 in)

226RS040

Clutch Hub Spline Play

1. Set a dial indicator to the clutch hub to measured.
2. Move the clutch hub as far as possible to both the right

and the left.
Note the dial indicator reading.

3. If the measured value exceeds the specified limit, the

clutch hub must be replaced.

Clutch hub spline play
Standard : 0–0.1 mm (0–0.004 in)
Limit : 0.2 mm (0.008 in)

226RS042

Bearings

1. Inspect the condition of all the needles and ball

bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.

NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.

2. Lubricate the bearings with a light oil and check them

for roughness by slowly turning the race by hand.

Ball Bearing Play

1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the

ball bearing must be replaced.

Limit : 0.2 mm (0.008 in)

226RS043

Synchronizers

The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:

D

Teeth for wear, scuffs, nicks, burrs or breaks.

D

Keys and springs for wear, cracks or distortion,
replace if these conditions are present.

D

If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace the
component.

Block Ring and Insert Clearance

1. Use a vernier caliper to measure the clearance

between the block ring and the insert.

2. If the measured value exceeds the specified limit, the

block ring and the insert must be replaced.

Block ring and insert clearance
Standard : 2.46–2.74 mm (0.097–0.108 in)

TRANSFER CASE (STANDARD TYPE)

4D1–35

Limit : 3.0 mm (0.118 in)

226RS037

2WD–4WD 3–Cone Synchronizer (Shift On
The Fly model)

1. Use a thickness gauge to measure the clearance

between the block ring and the dog teeth.

2. If the measured value exceeds the specified limit, the

2WD–4WD synchronizer assembly must be
replaced.

Block ring and insert clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 mm (0.031 in)

226RW142

Clutch Hub and Insert Clearance

1. Use a thickness gauge to measure the clearance

between the clutch hub and the insert.

2. If the measured value exceeds the specified limit, the

clutch hub and the insert must be replaced.

Clutch hub and insert clearance
Standard : 0.01–0.19 mm (0.0004–0.0075 in)
Limit : 0.3 mm (0.012 in)

226RS038

Detent Springs

1. Inspect the springs for distortion, cracks or wear.

Replace if these conditions are present.

Detent Spring Free Length

1. Use a vernier caliper to measure the detent spring

free length.

4D1–36 TRANSFER CASE (STANDARD TYPE)

2. If the measured value is less than the specified limit,

the detent spring must be replaced.

Detent spring free length

Detent ball
Standard : 23.4 mm (0.921 in)
Limit : 22.8 mm (0.898 in)

Interlock pin
Standard : 1.59 mm (0.063 in)
Limit : 1.53 mm (0.060 in)

220RW035

Detent Spring Tension

1. Use a spring tester to measure the detent spring

tension.

2. If the measured value is less than the specified limit,

the detent spring must be replaced.

Detent spring free length

Detent ball
Compressed height : 18.7 mm (0.736 in)
Standard : 68.6–88.2 N (7.0–9.0kg/15.4–19.8 lb)

Interlock pin
Compressed height : 11.5 mm (0.453 in)
Standard : 9.8 N (1.0kg/2.2 lb)

220RS013

Shift Arm

1. Inspect the shift arms for wear, distortion or scoring.

Replace if these conditions are present.

Shift Arm Thickness

1. Use a micrometer to measure the shift arm thickness.
2. If the measured value is less than the specified limit,

the shift arm must be replaced.

Shift arm thickness
Standard : 9.60–9.85 mm (0.378–0.388 in)
Limit : 9.0 mm (0.354 in)

230RS006