Opel Frontera UE. Manual - part 106

TRANSFER CASE

4D–11

Transfer Rear Case Assembly (A/T)

Transfer Rear Case Assembly (A/T) 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

Removal

1. Remove the speedometer sensor (1).
2. Remove the plate (1).

3. Remove the speedometer driven gear bushing and

driven gear (1).

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

4D–12

TRANSFER CASE

4. Remove front companion flange (2) and rear

companion flange (3), using the flange companion
holder 5–8840–0133–0 to remove the end nut..

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5. Remove the front and rear companion flange.

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

6. Disconnect the actuator breather hose and transfer

breather hose from control box (4).

7. Remove control box assembly (4).
8. Disconnect the actuator breather hose and

2WD–4WD actuator heat protector (5) from the
2WD–4WD actuator assembly (6).

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9. Remove the 2WD–4WD actuator assembly bolts.

10. Pull the 2WD–4WD actuator assembly (6) with

2WD–4WD shift rod.

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Legend

(6) 2WD–4WD Actuator Assembly
(7) Rear Cover Assembly
(9) Shift Rod: 2WD–4WD (Position: 2WD)

(10) Pull

(11) Position: 4WD

(12) Mode: 2WD

TRANSFER CASE

4D–13

11. Off set the actuator assembly.

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12. Remove the actuator assembly (6).

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Legend

(13) Position: 4WD
(14) Mode: 2WD

13. Remove transfer rear cover assembly (7) from

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 transfer rear cover assembly (7) to transfer

case assembly (8).

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 (15)

should align with that of the rear case hole’s
stopper (16).

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4D–14

TRANSFER CASE

4. Tighten the transfer rear case bolts to the specified

torque.

Torque: 37 N·m (3.8 kg·m/27 lb ft)

5. Shift the 2WD–4WD shift rod (17) to the 4WD side.
6. Join the rod grooves of 2WD–4WD actuator

assembly (6) and shift rod (17).

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Legend

(6) 2WD–4WD Actuator Assembly (Mode: 2WD)
(7) Rear Cover Assembly

(17) Shift Rod: 2WD–4WD (Position: 4WD)

7. Push the 2WD–4WD actuator assembly (6) with

2WD–4WD shift rod (17) till the shift rod (17) reaches
the 2WD position.

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Legend

(18) Position: 2WD
(19) Mode: 2WD

8. Tighten the 2WD–4WD actuator bolts to the specified

torque.

Torque: 19 N·m (1.9 kg·m/14 lb ft)

9. Connect the actuator breather hose to actuator.

10. Install actuator heat protector (5).

11. Install control box assembly (4).

Torque: 19 N·m (1.9 kg·m/14 lb ft)

12. Connect breather hoses to control box (4).
13. Install rear companion flange (3) and front companion

flange (2), using the companion flange holder
5–8840–0133–0 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 (17.0 kg·m/123
lb ft)
Front companion flange: 137 N·m (14.0 kg·m/101
lb ft)