Opel Frontera UBS. Service manual — part 1077
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4D2–24 TRANSFER CASE (TOD)
Disassembly
1. Remove the ball bearing (for front output shaft).
2. Expand the snap ring through the opening in the
planetary gear assembly.
261RW040
3. While expanding the snap ring, remove the input
shaft, ball bearing, carrier assembly, and thrust plate
from the transfer case.
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4. Remove the snap ring from the transfer case.
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5. Using snap ring pliers, remove the snap ring before
the ball bearing.
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4D2–25
TRANSFER CASE (TOD)
6. Using the bearing remover 5-8840-0015-0
(J-22912-01), remove the ball bearing from the input
shaft.
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7. Remove the thrust plate.
8. Remove the carrier assembly.
9. Remove the snap ring from the carrier assembly.
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10. Remove the circular hub.
11. Remove the snap ring before the ring gear.
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12. Using the replacer 5-8840-2413-0 (J-42806), remove
the ring gear.
NOTE: Removing the ring gear needs a high-load press.
This means the transfer case may be damaged. To
remove and replace the ring gear, it is recommended that
the transfer case assembly should be replaced.
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4D2–26 TRANSFER CASE (TOD)
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Inspection and Repair
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 solvent, 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
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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Lock-up Sleeve
Mount the mechanical lock hub, drive sprocket
assembly, and lock-up sleeve to the output shaft.
If the lock-up sleeve does not move smoothly, replace
the sleeve.
NOTE: Apply ATF to the area engaging the gear.
Thickness of Lock-up Sleeve
D
If the measurement exceeds the limit, replace the
lock-up sleeve.
Standard : 7.16-7.32 mm (0.282-0.288 in)
Allowable limit : 7.9 mm (0.311 in)
266RW014
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4D2–27
TRANSFER CASE (TOD)
Reduction Fork
Check the reduction fork and shaft for wear, distortion,
and scratches. If defects are observed, replace the
parts.
Thickness of Reduction Fork
D
If the measurement exceeds the limit, replace the
reduction fork.
Standard : 3.41-3.79 mm (0.134-0.149 in)
Allowable limit : 4.4 mm (0.173 in)
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Lock-up Fork
D
Check the lock-up fork and shaft for wear, distortion,
and scratches. If defects are observed, replace the
parts.
Thickness Lock-up Fork
If the measurement exceeds the limit, replace the
lock-up fork.
Standard : 6.99-7.09 mm (0.275-0.279 in)
Allowable limit : 6.3 mm (0.248 in)
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Bearing
Check the profile of the needle, roller, ball, and thrust
bearings. Wash the bearings with clean solvent
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.
D
Use a dial indicator to measure the ball bearing play.
Allowable limit : 0.23 mm (0.009 in)
226RW143
Lock-up Fork Spring
Check the lock-up fork spring for distortion, cracking,
and wear. If defects are observed, replace the part.
Free Length of the Lock-up Fork Spring
D
If the measurement exceeds the limit, replace the
spring.
Standard : 60.96 mm (2.40 in)
Allowable limit : 55.0 mm (2.17 in)
220RW045
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