1998 OPEL FRONTERA Back

4A1–13 DIFFERENTIAL (FRONT)
3. Clean the side bearing bores. Install the dial
indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
To r q u e : 9 8 N ꞏm ( 1 0 k g ꞏm / 7 2 l b f t )
415RS010
Legend
(1) Dial Indicator: 5–8840–0126–0
(2) Disc (2 pcs.): 5-8840-2088-0
(3) Arbor: 5–8840–0128–0
(4) Gauge Plate: 5–8840–2087–0
4. Set the dial indicator to “0”. Place it on the
mounting post of the gauging arbor with the
contact button touching the indicator pad. Force
the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the dial
indicator in this position.
425RS020
Legend
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gauge Plate
5. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate
the position at which the dial indicator shows the
greatest defection. At this point, once again set
the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.
425RS021
6. After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does not
touch the gauging plate.
Record the number the dial indicator needle
points to.
425RS022
Legend
(1) Example=Dial indicator reading of 0.085

DIFFERENTIAL (FRONT) 4A1–18
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash: 0.13–0.18 mm(0.005 –0.007 in)
425RS032With zero end play and correct backlash estab-
lished, remove the feeler gauge packs, determine
the thickness of the shims required and add 0.05
mm (0.002 in) to each shim pack to provide side
bearing preload. Always use new shims.
5. Use bearing remover 5–8840–0013–0 and
5–8840–0014–0 and pilot 9–8521–1743–0 to
remove side bearing.
415RW020
13. Install the side bearings together with the selected
shims.
425RS029
Legend
(1) Drive Handle:5–8840–0007–0
(2) Installer: 9–8522–1164–0
(3) Pilot: 9–8521–1743–0
14. Install side bearing outer race.
15. Install differential cage assembly.
16. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035

4A1–23 DIFFERENTIAL (FRONT)
Clearance between the side gear and the
differential box:
Standard: 0.03–0.10 mm (0.001–0.004 in)
Limit: 0.15 mm(0.006 in)
425RS046
Legend
(1) Side Gear
(2) Differential Box
Play in splines between the side gear and
the axle shaft:
Standard: 0.08–0.36 mm(0.003 –0.014 in)
Limit:0.5m (0.02 in)
425RS047
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.
425RS048
4. Install cross pin.
1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
2. Adjust the backlash between the side gear and
the pinion gear.
Backlash:0.03 – 0.08 mm (0.001– 0.003 in)

DIFFERENTIAL (REAR 220mm)
4A2A–3
Diagnosis
Many noises that seem to come from the rear axle
actually originate from other sources such as tires, road
surface, wheel bearings, engine, transmission, muffler, or
body drumming. Investigate to find the source of the
noise before disassembling the rear axle. Rear axles, like
any other mechanical device, are not absolutely quiet but
should be considered quiet unless some abnormal noise
is present.
To make a systematic check for axle noise, observe the
following:
1. Select a level asphalt road to reduce tire noise and
body drumming.
2. Check rear axle lubricant level to assure correct level,
and then drive the vehicle far enough to thoroughly
warm up the rear axle lubricant.
3. Note the speed at which noise occurs. Stop the
vehicle and put the transmission in neutral. Run the
engine speed slowly up and down to determine if the
noise is caused by exhaust, muffler noise, or other
engine conditions.
4. Tire noise changes with different road surfaces; axle
noises do not. Temporarily inflate all tires to 344 kPa
(3.5kg/cm
2, 50 psi) (for test purposes only). This will
change noise caused by tires but will not affect noise
caused by the rear axle.
Rear axle noise usually stops when coasting at
speeds under 48 km/h (30 mph); however, tire noise
continues with a lower tone. Rear axle noise usually
changes when comparing pull and coast, but tire
noise stays about the same.
Distinguish between tire noise and rear axle noise by
noting if the noise changes with various speeds or
sudden acceleration and deceleration. Exhaust and
axle noise vary under these conditions, while tire
noise remains constant and is more pronounced at
speeds of 32 to 48 km/h (20 to 30 mph). Further check
for tire noise by driving the vehicle over smooth
pavements or dirt roads (not gravel) with the tires at
normal pressure. If the noise is caused by tires, it will
change noticeably with changes in road surface.
5. Loose or rough front wheel bearings will cause noise
which may be confused with rear axle noise; however,
front wheel bearing noise does not change when
comparing drive and coast. Light application of the
brake while holding vehicle speed steady will often
cause wheel bearing noise to diminish. Front wheel
bearings may be checked for noise by jacking up the
wheels and spinning them or by shaking the wheels to
determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise when correctly
installed. Check to see that there is no link or rod
loosened or metal–to–metal contact.
7. Make sure that there is no metal–to–metal contact
between the floor and the frame.
After the noise has been determined to be in the axle, the
type of axle noise should be determined, in order to make
any necessary repairs.
Gear Noise
Gear noise (whine) is audible from 32 to 89 km/h (20 to 55
mph) under four driving conditions.
1. Driving under acceleration or heavy pull.
2. Driving under load or under constant speed.
3. When using enough throttle to keep the vehicle from
driving the engine while the vehicle slows down
gradually (engine still pulls slightly).
4. When coasting with the vehicle in gear and the throttle
closed. The gear noise is usually more noticeable
between 48 and 64 km/h (30 and 40 mph) and 80 and
89 km/h (50 and 55 mph).
Bearing Noise
Bad bearings generally produce a rough growl or grating
sound, rather than the whine typical of gear noise.
Bearing noise frequently “wow–wows” at bearing rpm,
indicating a bad pinion or rear axle side bearing. This
noise can be confused with rear wheel bearing noise.
Rear Wheel Bearing Noise
Rear wheel bearing noise continues to be heard while
coasting at low speed with transmission in neutral. Noise
may diminish by gentle braking. Jack up the rear wheels,
spin them by hand and listen for noise at the hubs.
Replace any faulty wheel bearings.
Knock At Low Speeds
Low speed knock can be caused by worn universal joints
or a side gear hub counter bore in the cage that is worn
oversize. Inspect and replace universal joints or cage and
side gears as required.
Backlash Clunk
Excessive clunk on acceleration and deceleration can be
caused by a worn rear axle pinion shaft, a worn cage,
excessive clearance between the axle and the side gear
splines, excessive clearance between the side gear hub
and the counterbore in the cage, worn pinion and side
gear teeth, worn thrust washers, or excessive drive pinion
and ring gear backlash. Remove worn parts and replace
as required. Select close–fitting parts when possible.
Adjust pinion and ring gear backlash.

4A2A–14
DIFFERENTIAL (REAR 220mm)
4. Set the dial indicator to “0”. Place it on the
mounting post of the gauging arbor with the
contact button touching the indicator pad. Force
the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the dial
indicator in this position.
425RS020
Legend
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gauge Plate
5. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate
the position at which the dial indicator shows the
greatest defection. At this point, once again set
the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.
425RS021
6. After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does not
touch the gauging plate.Record the number the dial indicator needle
points to.
425RS022
Legend
(1) Example=Dial indicator reading of 0.085
7. Record the pinion depth code on the head of the
drive pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indi-
cates the need for a greater mounting distance
(which can be achieved by decreasing the shim
thickness). A minus number indicates the need
for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If ex-
amination reveals pinion depth code “0”, the pin-
ion is “nominal”.
425RS023
8. Select the shim using the chart;

4A2A–18
DIFFERENTIAL (REAR 220mm)
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash: 0.15–0.2 mm(0.006 –0.008 in)
425RS032With zero end play and correct backlash estab-
lished, remove the feeler gauge packs, determine
the thickness of the shims required and add 0.05
mm (0.002 in) to each shim pack to provide side
bearing preload. Always use new shims.
5. Use bearing remover 5–8840–0013/0014–0 and
pilot 5–8840–2196–0 to remove side bearing.
415RW032
13. Install the side bearings together with the selected
shims.
425RS029
Legend
(1) Drive Handle: 5–8840–0007–0
(2) Installer: 5–8840–2162–0
(3) Pilot: 5–8840–2196–0
14. Install side bearing outer race.
15. Install differential cage assembly.
16. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035

DIFFERENTIAL (REAR 220mm)
4A2A–23
Clearance between the side gear and the
differential box:
Standard: 0.05–0.12 mm (0.002–0.005 in)
Limit: 0.15 mm(0.006 in)
425RS046
Legend
(1) Side Gear
(2) Differential Box
Play in splines between the side gear and
the axle shaft:
Standard: 0.07–0.38 mm(0.003 –0.014 in)
Limit:0.5m (0.02 in)
425RS047
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.
425RS048
4. Install cross pin.
1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
2. Adjust the backlash between the side gear and
the pinion gear.
Backlash:0.13 – 0.18 mm (0.005– 0.007 in)

DIFFERENTIAL (REAR 220mm)
4A2A–29
Measure the length between the plates over the
V–groove. (D)
425RS065
3. After measuring dimensions A,B,C and D, make
adjustment in the following manner:
Measure the thickness (E) of the spring disc.
1.75mm (0.069in)
4discs
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness :1.75–1.85mm(0.069–0.073 in)
Backlash adjustment of the side gear in
the direction of the shaft
1. Measuring the depth of the differential cage.
(F–B): 82.03 mm (3.23 in)
(G): 12.03 mm (0.47 in)
425RS066
2. Measuring the dimension between the thrust washers
at both ends.
Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.
Have the side gear contact to the pinion to make the
backlash 0.
Measure the dimension (H) between thrust
washers at both ends.
425RS067