Removal and installation the gearbox together with the transfer case (Opel Frontera B)

Warning! Before removing the transmission together with the transfer case from the vehicle, use the switch located on the instrument panel to switch the transfer case from 2WD mode to 4WD mode.

Removal

Disconnect the cable from the negative battery terminal.

Remove the gearshift lever (see the relevant chapter).



Remove the transfer case control lever (see the relevant chapter).

Raise the car.

Remove the gearbox guard (1) and plate (3).



Remove the front exhaust pipes (2 and 4) (the picture shows the 6VD1-W engine).



Mark the relative positions of the propeller shaft flanges and drive flanges on the front and rear axles, then remove the propeller shafts.

Disconnect the fuel lines from the clamps located on the side of the transmission housing.



Disconnect the wiring harness connectors from the oxygen concentration sensor (1 and 9, only on vehicles with 6VD1-W engine), transfer case switch (2), speed sensor (3), 4WD drive (4), magnetic sensor (5), main connector (6), transfer case mode switch (7) and case adapter (8).



Release the wire harness from the clamps (arrows) located on the gearbox.



On a vehicle with a 6VD1-W engine, remove the bolts and heat shield from the wiring harness.





Use a jack to support the gearbox through a wooden block.

Loosen the nuts securing the gearbox support to the rear beam.



Loosen the nuts that connect the transmission fluid tubes that connect the gearbox to the heat exchanger, release the tubes from the clamps, loosen the clamps, disconnect the tubes from the hoses and remove the tubes from the vehicle.

Note: To prevent dirt and dust from entering the gearbox, close the pipes and hoses with suitable plugs.

Disconnect the transmission control cable from the transmission.



Remove the starter (see the relevant chapter).

Remove the inspection covers from the clutch housing and engine.



Through the hole for installing the starter, unscrew the torque converter mounting bolts, while turning the engine crankshaft to consistently access the bolts.



Remove the bolts securing the gearbox to the engine.



Lift the transmission away from the engine, then slowly lower and remove the transmission from under the vehicle.

Warning! When removing the gearbox, do not damage nearby components or the vehicle body.

Installation

Clean the mating surfaces of the gearbox housing and engine.

Before installing the gearbox, lubricate the coupling sleeve (arrow) with lithium-based grease.



Use a jack to raise the transmission so that the front of the transmission is aligned with the rear of the engine.

Tighten the transmission-to-engine mounting bolts as follows:

• bolts A: 76 Nm
• bolts B: 8 Nm
• bolts C: 40 Nm

Through the hole for installing the starter, screw in the bolts securing the torque converter to the flywheel, while turning the engine crankshaft to consistently access the bolts. Tighten the bolts to 54 Nm.



Install the inspection covers on the clutch and engine housings and secure with bolts, tightening them to a torque of 8 Nm.

Install the starter (see the relevant chapter).

Connect the transmission control cable to the transmission (see the relevant chapter).



Install and connect the transmission fluid tubes connecting the transmission to the heat exchanger. Tighten the pipe union nuts to 44 Nm.





Install the rear beam on the vehicle chassis and secure with bolts, tightening them to a torque of 76 Nm.

Use nuts to secure the gearbox support to the rear beam and tighten them to a torque of 50 Nm.



On a vehicle with a 6VD1-W engine, install the heat shield for the wiring harness and secure with bolts, tightening them to a torque of 8 Nm.



Secure the wiring harness with the clamps located on the gearbox.

Connect the wire harness connectors to the oxygen sensor (only on vehicles with 6VD1-W engine), transfer case switch, speed sensor, 4WD drive, magnetic sensor, main connector, transfer case mode switch and case adapter.

Secure the fuel lines with the clamps located on the side of the gearbox housing.





Install the front exhaust pipes (2 and 4) (the picture shows the 6VD1-W engine).

Install the gearbox guard (1) and plate (3).

Align the previously applied marks and connect the rear propeller shaft flanges to the gearbox and rear axle and secure them with bolts and nuts, tightening them to a torque of 63 N·m.



Install the transfer case control lever (see the relevant chapter).



Install the gearshift lever (see the relevant chapter).



Connect the cable to the negative terminal of the battery.