Opel Frontera UBS. Manual - part 2027

4D2–31

TRANSFER CASE (TOD)

3. Using the front output shaft oil seal installer

5-8840-2410-0 (J-42807), install the oil seal to the
transfer case.

261RW053

Front 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 : 0.93 — 1.43mm (0.037 — 0.056 in)

A04RW003

4. Using the input shaft (main) oil seal installer

5-8840-2411-0 (J-42808), install the oil seal to the
transfer case.

261RW055

Input 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 : 3.25 — 3.75mm (0.13 — 0.15 in)

A04RW002

4D2–32 TRANSFER CASE (TOD)

5. Using the installer 5-8840-2416-0 (J-42809), press-fit

the ring gear.

Pay attention to the following points.

D

Identify the correct direction of gear.

D

Do not damage the gear.

D

Do not press-fit the ring gear slantingly.

D

Press-fit the ring gear to the innermost.

D

Remove burrs generated by press-fitting.

D

If the transfer case has serrations, match them with
those of the gear and press-fit the gear.

261RW054

261RW034

6. Install the snap ring to the transfer case.
7. Install the circular hub.
8. Install the snap ring to the carrier.
9. Mount the carrier assembly to the input shaft.

10. Check the direction of thrust plate and mount it to the

input shaft.

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11. Mount the ball bearing to the input shaft so that the

snap ring will be installed to the input shaft.

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12. Install the snap ring to the input shaft.
13. Install the snap ring to the transfer case.

4D2–33

TRANSFER CASE (TOD)

14. Using the snap ring pliers, expand the snap ring

through the opening between the ring gear and carrier
assembly and securely install the input shaft and
carrier assembly.

261RW038

15. Install the ball bearing (for front output shaft)

4D2–34 TRANSFER CASE (TOD)

Output Shafts and Shift Control Shaft

Disassembled View

261RW010–1

Legend

(1) Transfer Case Assembly
(2) Detent Spring
(3) Front Output Shaft
(4) Reduction Hub
(5) Output Shaft
(6) Reduction Fork Assembly
(7) Lock-up Shaft
(8) Spring Pin
(9) Reduction Fork

(10) Cam Assembly

(11) Snap Ring

(12) Washer
(13) Cam
(14) Cam Pilot Block
(15) Shifter Shaft Assembly
(16) Shifter Lever Shaft
(17) Snap Ring
(18) Reduction Lever Assembly
(19) Snap Ring

Reassembly

1. Apply ATF to the inside of the ball bearing for the front

output shaft.