Opel Frontera UBS. Service manual — part 1062

4D1–10 TRANSFER CASE (STANDARD TYPE)

Installation

To install, follow the removal steps in the reverse order,
noting the following points:

1. Apply a thin coat of molybdenum disulfide grease to

the input shaft spline and install the transter case
assembly to the vehicle.

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2. Tighten the transmission–transfer bolts and the nut

(M/T) to the specified torque.

Torque: 46 N·m (4.7kg·m/34 lb ft)

3. Tighten the propeller shaft bolts to the specified

torque.

Torque: 63 N·m (6.4kg·m/46 lb ft)

4. Tighten the transfer protector bolts to the specified

torque.

Torque: 37 N·m (3.8kg·m/27 lb ft)

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TRANSFER CASE (STANDARD TYPE)

4D1–11

Transfer Rear Cover Assembly (4WD Switch Model)

Transfer Rear Cover Assembly and Associated Parts

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Legend

(1) Speedometer Sensor, Speedometer Driven

Gear and Plate

(2) Front Companion Flange
(3) Rear Companion Flange

(4) Control Box Assembly
(5) 2WD–4WD Actuator Heat Protector
(6) 2WD–4WD Actuator Assembly
(7) Transfer Rear Cover Assembly
(8) Transfer Case Assembly

4D1–12 TRANSFER CASE (STANDARD TYPE)

Removal

1. Remove the speedometer sensor.
2. Remove the plate.
3. Remove the speedometer driven gear bushing and

driven gear.

NOTE: Apply a reference mark to the driven gear bushing
before removal.

4. Remove the front companion flange and the rear

companion flange, using the flange companion holder
5–8840–0133–0 (J–8614–11) to remove the end
nuts.

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NOTE: Use a universal puller to remove the rear
companion flange.

5. Disconnect the actuator breather hose and the

transfer breather hose from the control box.

6. Remove the control box assembly.
7. Disconnect the actuator breather hose and remove

the 2WD–4WD actuator heat protector from the
2WD–4WD actuator assembly.

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8. Remove the 2WD–4WD actuator assembly bolts.
9. Pull the 2WD–4WD actuator assembly with

2WD–4WD shift rod.

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Legend

(1) Shift Rod: 2WD–4WD (Position: 2WD)
(2) 2WD–4WD Actuator Assembly
(3) Pull Cover
(4) Rear Cover Assembly
(5) Position: 4WD
(6) Mode: 2WD

TRANSFER CASE (STANDARD TYPE)

4D1–13

10. Offset the actuator assembly.

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11. Remove the actuator assembly.

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Legend

(7) Position: 4WD
(8) Mode: 2WD

12. Remove the transfer rear cover assembly from the

transfer case assembly.

Installation

1. Apply the recommended liquid gasket (LOCTITE

17430) or its equivalent to the transfer rear cover
fitting faces.

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2. Install the transfer rear cover assembly to the transfer

case assembly.

3. Perform the following steps before fitting the transfer

rear case:
1. Shift the high–low shift rod to the 4H side.

2. The cut–away portion of the select rod head (9)

should align with that of the rear case hole’s
stopper (10).

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4. Tighten the transfer rear case bolts to the specified

torque.

Torque: 37 N·m (3.8kg·m/27 lb ft)

5. Shift the 2WD–4WD shift rod (11) to the 4WD side.