Opel Frontera UBS. Service manual — part 177
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.
260RW001
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)
256RW030
TRANSFER CASE (STANDARD TYPE)
4D1–11
Transfer Rear Cover Assembly (4WD Switch Model)
Transfer Rear Cover Assembly and Associated Parts
220RW102
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.
262RW067
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.
220RW085
8. Remove the 2WD–4WD actuator assembly bolts.
9. Pull the 2WD–4WD actuator assembly with
2WD–4WD shift rod.
220RW027
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.
220RW028
11. Remove the actuator assembly.
220RW029
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.
220RS017
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).
230RW004
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.
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