Opel Frontera UBS. Service manual — part 2024

4D2–19

TRANSFER CASE (TOD)

3. Remove the drive sprocket, lower driven sprocket,

and chain together from the front and rear output
shafts.

266RW010

4. Remove the mechanical lock hub.
5. Remove the lock-up fork.
6. Remove the spring retainers from the connection

between the rail shaft and lock-up fork.

7. Remove the lock-up sleeve.

261RW018

8. Remove the thrust washer.
9. Remove the magnet from the strainer set position

together with the oil pump assembly.

10. Remove the strainer from the oil pump assembly.

11. Remove the hose from the oil pump assembly.

4D2–20 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

4D2–21

TRANSFER CASE (TOD)

Disassembly

1. Remove the output shaft.

266RW011

2. Remove the detent spring.
3. Remove the cam pilot block bolts.
4. Remove the shifter shaft assembly and cam

assembly.

5. Remove the reduction fork assembly together with

reduction hub.

261RW019

6. Remove the spring pin that fixes the reduction fork to

the lock-up shaft.

261RW020

7. Remove the reduction fork.
8. Remove the lock-up shaft.
9. Using snap ring pliers, remove the snap ring from cam

pilot block.

261RW029

10. Remove the washer.

11. Remove the cam.

12. Remove the cam pilot block.

4D2–22 TRANSFER CASE (TOD)

13. Using snap ring pliers, remove the snap ring from the

shifter shaft assembly.

261RW021

14. Remove the reduction lever assembly.
15. Remove the snap ring.
16. Remove the shifter lever shaft.
17. Remove the front output shaft.

266RW012

18. Remove the transfer case assembly.