Opel Frontera UBS. Service manual — part 186
4D1–46 TRANSFER CASE (STANDARD TYPE)
Special Tools
ILLUSTRATION
PART NO.
PART NAME
5–8840–0015–0
(J–22912–01)
Bearing
remover/installer
5–8840–2279–0
(J–38592)
Transfer case oil seal
installer
5–8840–2156–0
(J–37219)
Mainshaft nut wrench
5–8840–2159–0
(J–37223)
Rear output shaft and
bearing installer
5–8840–2293–0
(J–39209)
Punch, end nut
5–8840–2281–0
(J–38594)
Front output shaft oil
seal installer
ILLUSTRATION
PART NO.
PART NAME
5–8840–2292–0
(J–39208)
Rear oil seal installer
5–8840–2192–1
(J–37486–A)
Bearing installer adapter
5–8840–0133–0
(J–8614–11)
Flange holder
5–8840–2155–0
(J–37217)
Mainshaft end bearing
remover
5–8840–2027–0
(J–37487)
Puller
5–8840–0007–0
(J–8092)
Driver handle
4D2–1
TRANSFER CASE (TOD)
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution
4D2–1
. . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly
4D2–2
. . . . . . . . . . . . . . . . .
Removal
4D2–2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
4D2–3
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal
4D2–5
. . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal and Associated
Parts
4D2–5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
4D2–5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
4D2–5
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU
4D2–7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
4D2–7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
4D2–7
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair
4D2–8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection
4D2–8
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case
4D2–9
. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
4D2–9
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–9
. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–10
. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Cover Assembly
4D2–12
. . . . . . . . . . . . . . . .
Disassembled View
4D2–12
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–12
. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–14
. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly Clutch Pack and
Clutch Cam
4D2–16
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
4D2–16
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–16
. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock
4D2–18
. . . . . . . . . . . .
Disassembled View
4D2–18
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–18
. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft
4D2–20
. . . . . .
Disassembled View
4D2–20
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–21
. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case
4D2–23
. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
4D2–23
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–24
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
4D2–26
. . . . . . . . . . . . . . . . . .
Transfer Case
4D2–30
. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
4D2–30
. . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–30
. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft
4D2–34
. . . . . .
Disassembled View
4D2–34
. . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–34
. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock
4D2–37
. . . . . . . . . . . .
Disassembled View
4D2–37
. . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–37
. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pack and Clutch Cam
4D2–39
. . . . . . . . . . . . .
Disassembled View
4D2–39
. . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–39
. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications
4D2–41
. . . . . . . . . . . . .
Special Tools
4D2–43
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
4D2–2
TRANSFER CASE (TOD)
Transfer Case Assembly
Removal
F07RW083
Legend
(1) Front Propeller Shaft
(2) Front Console
(3) Transfer Control Lever
(4) Selector Lever Assembly
(5) Transfer Connector
(6) Wiring Harness Connector
(7) Exhaust Pipe
(8) Rear Propeller Shaft
(9) Seat Belt Tension Rod
(10) Transfer Case Bolt
(11) Transfer Protector
(12) Breather Hose
(13) Transfer Case
1. Disconnect the ground cable.
2. Remove the transfer protector.
3. Remove the rear propeller shaft from the transfer
case.
4. Remove the front propeller shaft from the transfer
case.
5. Remove the shift control rod from the select lever
assembly.
4D2–3
TRANSFER CASE (TOD)
6. Disconnect the wiring harness connector and shift
lock cable and then remove the front console.
7. Remove the selector lever assembly and put it aside.
8. Remove the transfer control lever.
9. Disconnect the breather hose.
10. Remove the left front exhaust pipe fixing bolts and
nuts, and put the exhaust pipe aside.
11. Remove the left seat belt tension rod and put the rear
proper shaft aside.
260RW006
12. Remove the silencer.
13. Disconnect the transfer connector from the top of the
transfer case.
14. Disconnect the speed sensor harness connector.
15. Remove the fuel pipe clip fixing bolt on the transfer
case.
16. Support the transmission with a jack.
17. Remove the seven bolts from the transfer case.
18. Remove transfer case assembly.
Installation
To install, follow the removal steps in the reverse order,
nothing the following points:
1. Apply a thin coat of grease (Besco L2) or equivalent to
the input shaft spline.
261RW024
2. Mount the transfer case.
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