Opel Frontera UBS. Manual - part 2020

 

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Opel Frontera UBS. Manual - part 2020

 

 

4D2–3

TRANSFER CASE (TOD)

6. Disconnect the wiring harness connector, transfer

control lever knob and shift lock cable and then
remove the front console.

7. Remove the selector lever assembly and put it aside.
8. Remove the transfer control lever.
9. Disconnect the breather hose.

10. Remove the left front exhaust pipe fixing bolts and

nuts, and put the exhaust pipe aside.

11. Remove the left seat belt tension rod and put the rear

proper shaft aside.

260RW006

12. Disconnect the transfer harness connector from the

top of the transfer case.

13. Disconnect the speed sensor harness connector.
14. Remove the fuel pipe clip fixing bolt on the transfer

case.

15. Support the transmission with a jack.
16. Remove the seven bolts from the transfer case.
17. Remove the transfer case assembly.

Installation

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

1. Apply a thin coat of grease (Besco L2) or equivalent to

the input shaft spline.

261RW024

2. Mount the transfer case.

4D2–4

TRANSFER CASE (TOD)

3. Tighten the transfer case bolts (see the figure below).

Torque : 46 N·m (4.7 kg·m/34 lb ft)

261RW004–1

4. Tighten the propeller shaft bolts.

Torque : 63 N·m (6.4 kg·m/46 lb ft)

4D2–5

TRANSFER CASE (TOD)

Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts

261RW005

Legend

(1) Oil Seal
(2) End Nut and Rear Companion Flange

Removal

1. Remove the rear propeller shaft from the transfer

case.

2. Using the flange holder 5-8840-0133-0 (J-8614-11),

remove the end nut.

3. Using the universal puller, remove the rear

companion flange, washer and O-ring.

4. Remove the oil seal from the transfer rear case.

Installation

1. Apply engine oil to the oil seal outer surfaces.  Fill the

oil seal lip with grease (Besco L2).

261RW006

Legend

(1) Inside
(2) Outside

4D2–6

TRANSFER CASE (TOD)

2. Using the oil seal installer 5-8840-2412-0 (J-42804),

install the oil seal.

NOTE: When installing the oil seal, pay attention to the
direction.

261RW051

Rear Output Shaft Oil Seal

Distance between the transfer case end and oil seal.

NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.

Distance : 9.85 — 10.35mm (0.39 — 0.41 in)

A04RW004

3. Mount the rear companion flange, O-ring , washer,

and nut to the transfer case in this order.

4. Using the flange holder 5-8840-0133-0 (J-8614-11),

install a new end nut.

Torque : 167 N·m (17 kg·m /123 lb ft)

5. Using the punch 5-8840-2293-0 (J-39209), stake the

end nut at two spots.

NOTE: Check the staked end nut is free from cracks.

266RW028

260RW007

6. Install the rear propeller shaft to the transfer case and

tighten to the specified torque.

Torque : 63 N·m (6.4 kg·m /46 lb ft)

 

 

 

 

 

 

 

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