Opel Frontera UBS. Service manual — part 1080
4D2–36 TRANSFER CASE (TOD)
10. Install the reduction fork assembly together with
reduction hub to the transfer case assembly.
261RW019
11. Install the cam assembly and tighten the cam pilot
block set bolts to the specified torque.
Torque : 12 N·m (1.2 kg·m/104 lb in)
12. Tighten the detent spring to the specified torque.
Torque : 24 N·m (2.4 kg·m/17 lb in)
261RW022
13. Apply ATF to the needle bearing inside the input shaft
assembly.
14. Install the output shaft to the transfer case assembly.
4D2–37
TRANSFER CASE (TOD)
Sprocket and Mechanical Lock
Disassembled View
266RW008
Legend
(1) Strainer
(2) Hose
(3) Oil Pump Assembly
(4) Thrust Washer
(5) Mechanical Lock Hub
(6) Lock-up Sleeve
(7) Lock-up Fork
(8) Chain
(9) Lower Drive Sprocket
(10) Front Tone Wheel
(11) Drive Sprocket
(12) Sprocket Spacer
Reassembly
1. Connect the hose and strainer to the oil pump
assembly.
2. Install the oil pump assembly to the output shaft and
set the magnet to the strainer position.
3. Install the thrust washer.
4. Install the spring to the lock-up fork.
4D2–38 TRANSFER CASE (TOD)
5. Install the lock-up sleeve together with the lock-up
fork to the output shaft and lock-up shaft assembly.
6. Install the spring retainers to the lock-up fork.
261RW018
7. Install the mechanical lock hub.
8. Apply ATF to the chain.
9. Engage the chain to both sprockets.
10. Install the chain and sprocket assembly to both output
shafts.
266RW010
11. Install the front tone wheel and sprocket spacer.
4D2–39
TRANSFER CASE (TOD)
Clutch Pack and Clutch Cam
Disassembled View
266RW006
Legend
(1) Clutch Pack Assembly
(2) Insulator Washer
(3) Armature Plate
(4) Snap Ring
(5) Wave Spring
(6) Cam Pulley
(7) Cam Ball
(8) Cam and Coil Housing
(9) Thrust Bearing
Reassembly
1. Mount the clutch pack assembly to which the multi
plate disk clutch is already installed to the output
shaft.
NOTE: Mount the clutch pack assembly while adjusting
the phase of both the clutch housing and drive sprocket.
2. Install the insulator washer.
3. Install the armature plate.
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