Opel Frontera UE. Manual - part 1373

4D2–27

TRANSFER CASE (TOD)

4. Using the oil seal installer J–42808, install the input

shaft oil seal to the transfer case.

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5. Using the ring gear installer J–42809 and a bench

press, install the ring gear to the transfer case.

NOTE: Pay attention to the following points.

D

Identify the correct direction of gear.

D

Do not damage the gear.

D

Do not press-fit the ring gear slantingly.

D

Press-fit the ring gear to the innermost.

D

Remove burrs generated by press-fitting.

D

If the transfer case has serrations, match them with
those of the gear and press-fit the gear.

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6. Install the snap ring.
7. Install the thrust plate to the carrier assembly.

Attach the snap ring to the carrier assembly.

8. Install the carrier assembly to the input shaft.
9. With care the direction of circular hub, mount it to the

input shaft.

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10. Press the ball bearing to the input shaft so that the

snap ring will be attached to the input shaft.

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11. Install the snap ring to the input shaft.

12. Install the ball bearing of the front output shaft to the

transfer case.

SECTION

4D2–28 TRANSFER CASE (TOD)

13. Install the snap ring of the input shaft bearing to the

transfer case.

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14. Using snap ring pliers, open the snap ring from the

gap on the carrier assembly.
While opening the snap ring, securely attach the input
shaft and carrier assembly to the transfer case.

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Inspection and Repair (Transfer Case
Assembly)

When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.

Chain

D

Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.

D

If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.

Sprocket

D

Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.

D

If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.

Gear

D

Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.

Thickness of Reduction Hub

D

Measure the thickness with a micrometer.

D

If the measurement exceeds the limit, replace the
reduction hub.

Standard : 3.05–3.30 mm (0.120–0.130 in)

Allowable limit : 2.5 mm (0.098 in)

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SECTION

4D2–29

TRANSFER CASE (TOD)

Lockup Collar Assembly

D

Install the lockup hub, drive sprocket assembly, and
lockup collar assembly to the output shaft.

D

If the lockup collar assembly does not move
smoothly, replace the lockup collar assembly.

NOTE: Apply ATF to the rear engaging the gear.

Width of Lockup Collar

D

Using calipers, measure the lockup collar groove for
width of wear.

D

If the measurement exceeds the limit, replace the
lockup collar assembly.

Standard : 7.16–7.32 mm (0.282–0.288 in)

Allowable limit : 7.9 mm (0.311 in)

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Shift Fork and Rail Assembly

Check the shift fork and rail for wear, distortion, and
scratches. If defects are observed, replace the parts.

Thickness of Shift Fork

D

If the measurement exceeds the limit, replace the
shift fork.

Standard : 3.41–3.79 mm (0.134–0.149 in)

Allowable limit : 4.4 mm (0.173 in)

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Lockup Fork and Rail

D

Check the lockup fork and rail for wear, distortion, and
scratches. If defects are observed, replace the parts.

Thickness Lockup Fork

If the measurement exceeds the limit, replace the lockup
fork.

Standard : 6.99–7.09 mm (0.275–0.279 in)

Allowable limit : 6.3 mm (0.248 in)

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SECTION

4D2–30 TRANSFER CASE (TOD)

Bearing

Check the profile of the needle, roller, ball, and thrust
bearings. Wash the bearings with clean detergent
completely, and dry with air.

NOTE: If the bearing is rotated excessively, the rollers
may be damaged. So, rotate the bearing slowly with your
hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
with your hand.

Allowable limit : 0.23 mm (0.009 in)

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Lockup Fork Spring

Check the lockup fork spring for distortion, cracking, and
wear. If defects are observed, replace the part.

Multi Plate Disk Clutch

D

If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the parts.

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Legend

(1) Clutch Housing
(2) Clutch Plate
(3) Insulator Washer
(4) Armature Plate

Coil Assembly

D

Check the resistance of the coil with a tester. If
defects are observed, replace the coil assembly.

Standard : 1.7

±

0.3

W

 (at ordinary temperature)

Allowable limit : 1.0

∼

5.0

W

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Cam Pulley, Cam Ball, and Cam & Coil
Housing

D

Check the cam balls and cam for excessive wear or
damage. If defective, replace the parts.

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SECTION