Opel Frontera UBS. Manual - part 2017

 

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Opel Frontera UBS. Manual - part 2017

 

 

TRANSFER CASE (STANDARD TYPE)

4D1–37

Reassembly

1. Put the transfer case (with oil seal) as the following

illustration.

Input shaft oil seal (1) replacement

1. Remove the oil seal from the transfer case.

2. Apply engine oil to the oil seal outer surfaces.

3. Apply recommended grease (BESCO L2) or

equivalent to the oil seal lip.

4. Use the oil seal installer 5–8840–2279–0

(J–38592) to install the oil seal to the transfer
case.

220RW106

Front output shaft oil seal (2) replacement

1. Remove the oil seal from the transfer case.

2. Apply engine oil to the oil seal outer surfaces.

3. Apply recommended grease (BESCO L2) or

equivalent to the oil seal lip.

4. Use the oil seal installer 5–8840–2281–0

(J–38594) to install the oil seal to the transfer
case.

220RW107

Legend

(2) Front output shaft oil seal

2. Apply chassis grease (3) to the sub–gear (23) and the

counter gear (22) thrust surfaces.

226RW134

4D1–38 TRANSFER CASE (STANDARD TYPE)

3. Install the sub–gear (23) to the counter gear (22).
4. Install the belleville spring (24).
5. Install the spacer (25) and put the snap ring (29) on

the sub–gear (23).

6. Install the ball bearing (26), using a bench press.
7. Select a snap ring that will allow the minimum axial

play.

Clearance : 0–0.1 mm (0–0.004 in)

Snap ring availability:

Thickness

Color–coding

1.50 mm (0.059 in)

White

1.55 mm (0.061 in)

Yellow

1.60 mm (0.063 in)

Blue

8. Use a pair of snap ring pliers to install the snap ring

(27) to the counter gear (22).

226RS170

226RS021

Sub–Gear (anti–lash plate) Preload

1. Hook a length of piano wire (4) over one of the

sub–gear (5) teeth.

2. Attach the other end of the piano wire (4) to a

spring balancer.

3. Measure the sub–gear preload.

Preload : 59–98 N (6.0–10kg/13–22 lb)

226RS075

9. Install ball bearing (21), using a bench press.

10. Install snap ring (20).

11. Install the counter gear assembly (28) to the transfer

case (1).

12. Use a pair of snap ring pliers to install the snap ring

(29) to the transfer case (1).

NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.

13. Use a bench press to install the ball bearing (4) to the

front output shaft (5).

262RS012

TRANSFER CASE (STANDARD TYPE)

4D1–39

14. Assemble the 2WD–4WD clutch hub and sleeve

assembly (7).

226RW140

15. Engage the springs in the same insert with the open

ends away from each other. (Shift On The Fly model)

226RW141

16. Place the snap ring (2), a new stopper plate (6) (Shift

On The Fly model) and the clutch sleeve and hub
assembly (7) on the front output shaft (5).

226RW135

Legend

(6) Front Output Gear

17. The clutch hub face (with the heavy boss) must be

facing the front output gear side.

18. Use a bench press to slowly force the clutch hub and

sleeve assembly (7) together with the stopper plate
(6) (Shift On The Fly model) into place.

19. Align the inserts with the block ring insert grooves.

Install the block ring (8) (Shift On The Fly model) to
the clutch sleeve and hub assembly (7).

20. Install the outside ring (9) (Shift On The Fly model),

inside ring (10) (Shift On The Fly model) and needle
bearing (12) to the front output gear (11) and bearing
collar (17).

NOTE: Coat all parts with transmission oil before
installing them.

226RW139

4D1–40 TRANSFER CASE (STANDARD TYPE)

21. Apply engine oil to the thrust surfaces of the sub–gear

(13), the belleville spring (14), and the spacer (15).
(M/T)

262RW060

22. Install the sub–gear (anti–lash plate) (13), belleville

spring (14), and spacer (15) to the front output gear
(11).(M/T)

23. Install the sub–gear snap ring (16). (M/T)
24. Use a bench press to install the needle bearing collar

(17) together with the front output gear, aligning inside
ring claw with block ring groove.

262RS014

25. Install ball bearing (18), using a bench press.

26. Select a snap ring that will allow the minimum axial

play.

Clearance : 0–0.1 mm (0–0.004 in)

Snap ring availability:

Snap ring thickness

Color coding

1.55 mm (0.061 in)

White

1.60 mm (0.063 in)

Yellow

1.65 mm (0.065 in)

Blue

1.70 mm (0.067 in)

Pink

1.75 mm (0.069 in)

Green

1.80 mm (0.071 in)

Brown

1.85 mm (0.073 in)

Red

1.90 mm (0.075 in)

Orange

262RS015

226RS021

 

 

 

 

 

 

 

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