Opel Frontera UBS. Service manual — part 2028
4D2–35
TRANSFER CASE (TOD)
2. Mount the front output shaft to the transfer case.
266RW012
3. Install the shifter lever shaft to the transfer case
assembly.
4. Install the snap ring to the shifter lever shaft.
5. Install the reduction lever assembly to the shifter lever
shaft and fix the assembly with the snap ring.
261RW021
6. Install the cam to the cam pilot block.
7. Attach the washer to the cam pilot block and fix the
washer with the snap ring.
261RW029
8. Mount the reduction fork to the lock-up shaft.
9. Install the spring pin to the reduction fork and lock-up
shaft.
261RW020
4D2–36 TRANSFER CASE (TOD)
10. Install the reduction fork assembly together with
reduction hub to the transfer case assembly.
261RW019
11. Install the cam assembly and tighten the cam pilot
block set bolts to the specified torque.
Torque : 12 N·m (1.2 kg·m/104 lb in)
12. Tighten the detent spring to the specified torque.
Torque : 24 N·m (2.4 kg·m/17 lb in)
261RW022
13. Apply ATF to the needle bearing inside the input shaft
assembly.
14. Install the output shaft to the transfer case assembly.
4D2–37
TRANSFER CASE (TOD)
Sprocket and Mechanical Lock
Disassembled View
266RW008
Legend
(1) Strainer
(2) Hose
(3) Oil Pump Assembly
(4) Thrust Washer
(5) Mechanical Lock Hub
(6) Lock-up Sleeve
(7) Lock-up Fork
(8) Chain
(9) Lower Drive Sprocket
(10) Front Tone Wheel
(11) Drive Sprocket
(12) Sprocket Spacer
Reassembly
1. Connect the hose and strainer to the oil pump
assembly.
2. Install the oil pump assembly to the output shaft and
set the magnet to the strainer position.
3. Install the thrust washer.
4. Install the spring to the lock-up fork.
4D2–38 TRANSFER CASE (TOD)
5. Install the lock-up sleeve together with the lock-up
fork to the output shaft and lock-up shaft assembly.
6. Install the spring retainers to the lock-up fork.
261RW018
7. Install the mechanical lock hub.
8. Apply ATF to the chain.
9. Engage the chain to both sprockets.
10. Install the chain and sprocket assembly to both output
shafts.
266RW010
11. Install the front tone wheel and sprocket spacer.
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