Opel Frontera UBS. Manual - part 2025

4D2–23

TRANSFER CASE (TOD)

Transfer Case

Disassembled View

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Legend

(1) Transfer Case
(2) Ball Bearing
(3) Ring Gear
(4) Snap Ring
(5) Input Shaft and Carrier Assembly
(6) Snap Ring

(7) Ball Bearing
(8) Snap Ring
(9) Thrust Plate

(10) Carrier Assembly

(11) Snap Ring

(12) Circular Hub
(13) Input Shaft

4D2–24 TRANSFER CASE (TOD)

Disassembly

1. Remove the ball bearing (for front output shaft).
2. Expand the snap ring through the opening in the

planetary gear assembly.

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3. While expanding the snap ring, remove the input

shaft, ball bearing, carrier assembly, and thrust plate
from the transfer case.

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4. Remove the snap ring from the transfer case.

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5. Using snap ring pliers, remove the snap ring before

the ball bearing.

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4D2–25

TRANSFER CASE (TOD)

6. Using the bearing remover 5-8840-0015-0

(J-22912-01), remove the ball bearing from the input
shaft.

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7. Remove the thrust plate.
8. Remove the carrier assembly.
9. Remove the snap ring from the carrier assembly.

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10. Remove the circular hub.

11. Remove the snap ring before the ring gear.

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12. Using the replacer 5-8840-2413-0 (J-42806), remove

the ring gear.

NOTE: Removing the ring gear needs a high-load press.
This means the transfer case may be damaged.  To
remove and replace the ring gear, it is recommended that
the transfer case assembly should be replaced.

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4D2–26 TRANSFER CASE (TOD)

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Inspection and Repair

When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced.  Wash all the parts with clean solvent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed.  Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.

Chain

D

Check whether the face that contacts the sprocket is
free from excessive wear or damage.  If defects are
observed, replace the part.

D

If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.

Sprocket

D

Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline.  Remove minor flaws or scratches with oil
stone.  If excessive wear or damage is observed,
replace the part.

D

If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.

Gear

Check whether the gear tooth surface is excessively

worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone.  If
excessive wear or damage is observed, replace the
part.

Thickness of Reduction Hub

D

Measure the thickness with a micrometer.

D

If the measurement exceeds the limit, replace the
reduction hub.

Standard : 3.05-3.30 mm (0.120-0.130 in)

Allowable limit : 2.5 mm (0.098 in)

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Lock-up Sleeve

Mount the mechanical lock hub, drive sprocket

assembly, and lock-up sleeve to the output shaft.

If the lock-up sleeve does not move smoothly, replace

the sleeve.

NOTE: Apply ATF to the area engaging the gear.

Thickness of Lock-up Sleeve

D

If the measurement exceeds the limit, replace the
lock-up sleeve.

Standard : 7.16-7.32 mm (0.282-0.288 in)

Allowable limit : 7.9 mm (0.311 in)

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