Opel Frontera UE. Manual - part 1616

MANUAL TRANSMISSION

7B–13

7. Remove the speedometer sensor(7).

Remove the plate(7).
Remove the driven gear bushing and driven gear(7).

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

8. Remove front companion flange(8) and rear

companion flange(9) using the flange holder
5–8840–0133–0 to remove the end nut.

266RW026

9. Disconnect breather hose from transmission and

remove gear control box assembly(10).

10. Remove 2WD–4WD actuator assembly(11) by

performing the following steps:
1. Disconnect the actuator breather hose from

2WD–4WD actuator assembly(11).

220RW085–1

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

3. 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
(4) Rear Case Assembly
(5) Position: 4WD
(6) Position: 2WD

4. Offset the actuator assembly.

220RW028

SECTION

7B–14

MANUAL TRANSMISSION

5. Remove the actuator assembly.

220RW029

Legend

(7) Position: 4WD
(8) Mode: 2WD

NOTE: Before removing the transmission and transfer
assembly from vehicle, change the transfer mode to 2WD
using the 4WD push button switch on dash panel.

11. Remove the transfer rear cover assembly(12) from

the transfer case(28).

12. Regarding detent, shift arm, and interlock pin(13)

disassembly, refer to 

Detent, Shift Arm, and Interlock

Pin in Drive Line/Axle section.

13. Use a pair of snap ring pliers to remove the bearing

snap ring(14).

14. Use a bearing remover 5–8840–2155–0 and puller

5–8840–2027–0 to remove the ball bearing(15).

262RW069

15. Install the front companion flange temporarily.

Use the flange holder 5–8840–0133–0 and lock nut
wrench 5–8840–2156–0 to remove the lock nut(16).
Remove the front companion flange.

226RW190

16. Remove high-low clutch sleeve(17).

Use the universal puller to remove the high-low clutch
hub(17) and transfer input gear(18).

226RS070

SECTION

MANUAL TRANSMISSION

7B–15

17. Remove needle bearing(19), bearing collar(20),

ball(21), and plate(22).

226RS071

18. Use a pair of snap ring pliers to remove the bearing

snap ring(23).

19. Use a plastic hammer to tap the front output gear

assembly(24) free.

262RS009

20. Remove bearing snap ring(25) by using a pair of snap

ring pliers.

21. Remove the counter gear assembly(26) from the

transfer case(28).

22. Remove the transfer case assembly(28) from the

transmission case.

D

Refer to 

Transfer Case Assembly in Drive Line/Axle

section for repair of transfer case assembly.

23. Pull out intermediate plate with gear assembly(29)

from transmission case.

Reassembly

1. Apply recommended liquid gasket (LOCTITE 17430)

or its equivalent to the transmission case(30),
intermediate plate(29) and transfer case(28) fitting
surfaces.

2. Install the intermediate plate with gear assembly(29)

to the transmission case(30).
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or
stress.

3. Install the transfer case assembly(28) to the

intermediate plate with gear assembly.
Tighten the eight transmission-transfer case bolts to
the specified torque.

Torque: 37 N·m (3.8 kg·m/27 lb ft)

Refer to 

Transfer Rear Case Assembly in Drive

Line/Axle section for oil seal replacement.

4. Install the counter gear assembly(26) to the transfer

case(28).

5. Use a pair of snap ring pliers to install the snap

ring(25) to the transfer case(28).

NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.

6. Install front output gear assembly(24).
7. Use a pair of snap ring pliers to install the snap ring

(23) to the  transfer case(28).

NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.

8. Install plate(22), ball(21), bearing collar(20), needle

bearing(19), and transfer input gear(18).

9. Install High-low clutch hub and sleeve(17).

The clutch hub face (with the heavy boss) must be
facing the transfer input gear side.

226RW152

SECTION

7B–16

MANUAL TRANSMISSION

10. Install the front companion flange temporarily.

D

Use the flange holder 5–8840–0133–0 and lock nut
wrench 5–8840–2156–0 to install the lock nut(16).

Torque: 137 N·m (14.0 kg·m/101 lb ft)

226RW190

11. Use the punch to stake the lock nut at one spot.

12. Use a suitable drift and hammer to install the ball

bearing(15).

226RS079

13. Use a pair of snap ring pliers to install the bearing

snap ring(14).

14. Regarding detent, shift arm, and interlock pin(13)

assembly, refer to 

Detent, Shift Arm, and Interlock Pin

in Drive Line/Axle section.

15. Apply recommended liquid gasket (LOCTITE 17430)

or its equivalent to the transfer rear case fitting faces.

220RS017

16. Perform the following steps before fitting the transfer

rear cover(11):
1. Shift the High-Low shift rod to the 4H side.

2. The cut-away portion of select rod head should

align with the rear case hole’s stopper.

230RS002

17. Tighten the eleven transfer rear case bolts to the

specified torque.

Torque: 37 N·m (3.8 kg·m/27 lb ft)

SECTION