Opel Frontera UBS. Service manual — part 1063
4D1–14 TRANSFER CASE (STANDARD TYPE)
6. Join the rod grooves of 2WD–4WD actuator
assembly (12) and shift rod (11).
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Legend
(11) Shift Rod: 2WD–4WD (Position: 4WD)
(12) 2WD–4WD Actuator Assembly (Mode: 2WD)
(13) Rear Cover Assembly
7. Push the 2WD–4WD actuator assembly (12) with
2WD–4WD shift rod (11) till the shift rod (11) reaches
the 2WD position.
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Legend
(14) Position: 2WD
(15) Mode: 2WD
8. Tighten the 2WD–4WD actuator bolts to the specified
torque.
Torque: 19 N·m (1.9kg·m/14 lb ft)
9. Install the actuator heat protector.
10. Connect the actuator breather hose to the actuator.
11. Install the control box assembly.
Torque: 19 N·m (1.9kg·m/14 lb ft)
12. Connect the breather hoses to the control box.
13. Install the rear companion flange and front
companion flange, using the companion flange holder
5–8840–0133–0 (J–8614–11) to tighten the flange
nuts to the transfer case.
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14. Tighten the new transfer flange nuts to the specified
torque.
Torque
Rear companion flange: 167 N·m (17.0kg·m/123
lb ft)
Front companion flange: 137 N·m (14.0kg·m/101
lb ft)
15. Use the punch 5–8840–2293–0 (J–39209) to stake
the rear companion flange nut at two spots.
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TRANSFER CASE (STANDARD TYPE)
4D1–15
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16. Stake the front companion flange nut at one spot.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.
17. Install the O–ring (8) to the speedometer driven gear
bushing (7).
18. Install the driven gear to the speedometer driven gear
bushing (7).
19. Install the speedometer driven gear assembly to the
transfer rear cover.
20. Install the plate (6) to the transfer rear case and
tighten to the specified torque.
Torque: 15 N·m (1.5kg·m/11 lb ft)
21. Install the speedometer sensor and tighten to the
specified torque.
Torque: 27 N·m (2.8kg·m/20 lb ft)
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4D1–16 TRANSFER CASE (STANDARD TYPE)
Disassembly
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Legend
(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing
(5) Bearing Snap Ring
(6) Ball
(7) Speedometer Drive Gear
(8) Ball Bearing
(9) Transfer Rear Cover (with oil seal)
1. Remove the bearing snap ring (3), using a pair of snap
ring pliers.
226RS060
TRANSFER CASE (STANDARD TYPE)
4D1–17
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5–8840–0015–0 (J–22912–01) .
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4. Remove the speedometer drive gear (7).
5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01).
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Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Install transfer rear cover (with oil seal).
Oil seal replacement
D
Remove the oil seal from the transfer rear cover.
D
Apply engine oil to the oil seal outer surfaces.
D
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
D
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.
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2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).
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