Opel Frontera UBS. Service manual — part 1073
4D2–8
TRANSFER CASE (TOD)
Unit Repair
Inspection
Before disassembling and after assembling, check the
following items on the transfer connector terminals.
No.
NAME
CONTENTS
1
Ref . (Rr . )
Rear speed sensor
reference output
2
Ref . (Frt . )
Front speed sensor
reference output
3
SW GND
SW GND
4
4H SW (+)
4H SW plus terminal
5
Rer . (+)
Rear speed sensor plus
6
Frt . (+)
Front speed sensor plus
7
POWER GND
Power GND
8
EMC (+)
Electromagnetic coil
9
COM (–) (Rr .)
Rear speed sensor GND
10
COM (–) (Frt .)
Front speed sensor GND
11
NC
Not used
12
4L SW (+)
4L SW plus terminal
810RW002
4H and 4L switch
Check whether the 4H switch (terminals 4 and 7) and 4L
switch (terminals 12 and 3 ) work as specified in the table
below. If yes, the continuity is established on these
switches. If not, check the switches, shift rails, transfer
case, and rear cover, and replace the failed parts.
SHIFT
POSITION
PIN 4 (4 to 7)
4H SW
PIN 12 (3 to 12)
4L SW
HIGH
OFF
OFF
(NEUTRAL)
ON
ON
4L
OFF
ON
Power GND
Check that there is a continuity between the power GND
pin (terminal 7) and transfer case. If not, replace the
grounding wire.
Resistance of electromagnetic coil
Check the resistance between electromagnetic coil
(terminal 8) and power GND (terminal 7). If not, replace
the electromagnetic coil.
Standard : 1.4
∼
2.0
W
Allowable : 1.0
∼
5.0
W
4D2–9
TRANSFER CASE (TOD)
Transfer Case
Disassembled View
266RW004
Legend
(1) Front Companion Flange
(2) 4H and 4L Switch, Ground Cable, and Center
Connector
(3) Offset Lever
(4) Spring Pin
(5) Transfer Case Assembly
(6) Transfer Cover Assembly
(7) Rear Companion Flange
Disassembly
1. Remove the drain plug from the transfer case and
drain the oil.
2. Disconnect the 4H and 4L switch and ground cable.
3. Remove the clip fixing the harness.
4. Using the flange holder 5-8840-0133-0 (J-8614-11),
remove the flange nut, and remove front companion
flange.
5. Using the flange folder 5-8840-0133-0 (J-8614-11),
remove the flange nut, and remove rear companion
flange.
266RW005
4D2–10 TRANSFER CASE (TOD)
6. Remove the offset lever set bolt on the right side.
261RW015
7. Remove the offset lever lock spring pin.
NOTE: When removing the spring pin, note the recess
position of the pin.
261RW016
8. Remove the offset lever.
261RW017
9. Remove the sixteen bolts and detach the transfer
cover assembly from the transfer case assembly.
NOTE: When removing the transfer cover assembly, be
careful not to damage the oil seal.
Reassembly
1. Apply liquid gasket (Loctite 598 or equivalent)
uniformly to the mating face that contacts the transfer
case.
261RW023
4D2–11
TRANSFER CASE (TOD)
2. Tighten the sixteen bolts to the specified torque.
Torque : 31 N·m (3.2 kg·m/23 lb ft)
3. Wind the sealing tape around the drain plug thread
and tighten the plug to the specified torque.
Torque : 25 N·m (2.5 kg·m/18 lb ft)
4. Mount the offset lever to the transfer shift and install
the spring pin.
261RW016
5. Attach the O-ring and washer to the companion
flange.
NOTE: Securely push the O-ring to the hollow of the
companion flange, and then attach the washer.
6. Use the flange holder 5-8840-0133-0 (J-8614-11) to
tighten the flange nut.
7. Tighten the flange nut to the specified torque.
Torque : 167 N·m (17.0 kg·m/123 lb ft)
8. Using the punch 5-8840-2293-0 (J-39209), securely
stake the flange nut at two spots.
NOTE: Check the staked flange nut is free from cracks.
266RW028
260RW007
9. Fix the harness with the clip.
10. Tighten the 4L and 4H switch to the specified torque.
Torque : 24 N·m (2.4 kg·m/17 lb ft)
11. Fill the transfer case with ATF II or III (1.9 liters).
12. Wind the sealing tape around the filler plug thread and
tighten the plug to the specified torque.
Torque : 25 N·m (2.5 kg·m/18 lb ft)
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