Removal and installation the transfer case (Opel Frontera B)

Removal

Disconnect the cable from the negative battery terminal.

Remove the gearbox together with the transfer case (see the relevant chapter).

Remove both drain plugs and drain the transmission oil from the gearbox housing and transfer case into a suitable container.



Remove the rectangular shift housing from the transmission (see the relevant chapter).

Remove the transfer case mode shift drive (see the relevant chapter).

Using a special tool KM-468-C, hold the drive flange from turning, unscrew the nut and remove the flange from the transfer case.



Remove the cover with the driven gear of the vehicle speed sensor from the transfer case (see the relevant chapter).



Remove the bolts and remove the rear cover from the transfer case.



Remove the main shaft rear bearing retaining ring.

Using the KM-210-V puller (1) and the KM-775 extractor (2), remove the rear bearing from the main shaft.



Using the special tool KM-776-A, hold the main shaft from turning, and using the special tool KM-468-C, unscrew the nut securing the front output flange to the main shaft.



Using a two-jaw puller, remove the transfer case high/low clutch, bushing and input gear from the main shaft.





Remove the input gear needle bearing, inner race, locking ball and oil spray plate from the main shaft.



Remove the bolts and nuts and remove the front gearbox housing from the intermediate plate.

To prevent damage to the working edges of the seal, seal the splines of the main shaft with adhesive tape.

Installation

Install the high and low stage synchronizer sleeve or the clutch sleeve and sleeve.

Make sure that the larger boss on the sleeve (1) is aligned with the groove (2) on the sliding sleeve. The arrow points to the front of the transfer case.



Using a special device KM-468-C, hold the drive flange from turning, screw on and tighten the flange mounting nut to a torque of 137 N·m, then pin the nut in two places.





Install the oil spray plate (1), locking ball, inner race, input gear needle bearing (2), input gear (3), and transfer case high/low shift clutch (4) onto the main shaft.

Caution: Install the high/low clutch so that the larger lug on the sleeve faces the input gear.

Using the special tool KM-776-A, hold the main shaft from turning, use the special tool KM-468-C to tighten the main shaft nut to a torque of 137 N·m, then calk the nut in two places.



Using a tubular mandrel of the appropriate diameter, install the rear bearing onto the input shaft and secure it with a retaining ring.





Apply a thin layer of sealant to the mating surfaces of the transfer case housing and rear case.

Make sure the tab (A) on the high/low shift block fits into the 4x2/4x4 shift block.



Set the high and low gear shift rod to position 4H.

Install the rear transfer case housing. Align the shift rod (B) with the D-shaped hole (C) in the rear case.



Clean the threaded holes for the rear crankcase mounting bolts, then apply a layer of sealant to the bolt threads.



Install the rear crankcase mounting bolts and tighten to 37 Nm.

Using a special device KM-468-C, hold the drive flange from turning, screw on and tighten the flange mounting nut to a torque of 167 N·m, then pin the nut in two places.

[Material published on the website OPELBOOK]



Install the transfer case mode switching drive (see the relevant chapter).

Install the rectangular gearshift housing onto the transmission (see the relevant chapter).



Install new washers on the plugs and screw the oil drain plugs back into place.

Remove the oil level check plugs and washers. Pour the required amount of required oil through the oil level check plug holes until its level reaches the lower edge of the threaded hole.



Install new washers and tighten the oil level plugs.

Install the gearbox together with the transfer case (see the relevant chapter).

Connect the cable to the negative terminal of the battery.