1998 OPEL FRONTERA Differential oil

DIFFERENTIAL (REAR 220mm)
4A2A–27
Pressure ring
425RS057
Legend
(3) Sliding surface with the friction disc. When
nicks or scratches are found, polish with an oil
stone and repair on a level block using a
compound.
(4) Sliding spherical surface with the pinion gear.
(5) Sliding surface with the side gear.
(6) V–shaped groove of the pressure ring and V
–shaped section of the pinion shaft.
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case. Repair burrs and nicks using
an oil stone.
Thrust washer
425RS058
Legend
(9) Sliding surface with the side gear or case.
(10) Peripheral groove of the side gear.
Repair light nicks and burrs using an oil stone.
Case
425RS059
Legend
(11) Contact surface with the spring disc.
(12) Inner groove of the differential cage B.
Repair light nicks and burrs using an oil stone.
425RS060

4A2A–28
DIFFERENTIAL (REAR 220mm)
Legend
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case.
Repair burrs and nicks using an oil stone.
(9) Sliding surface with the side gear or case.
(11) Contact surface with spring disc.
Measure the Deformation of the friction disc & plate.
Limit: 0.08 mm (0.003 in)
425RS061
Measure the wear of the friction plate & disc
Limit(A–B): 0.1 mm (0.004 in)
Remarks:
A=Inner or outer projections
B=Sliding surface subjected to abrasion
425RS062
Measure the wear of the thrust washer
Limit: 1.3 mm (0.05 in)
425RS063
Reassembly
Adjust the clearance between the friction disc and plate.
1. Measuring the depth of the differential cage.
Standard (A–B): 80.58 mm (3.17 in)
(C): 10.58 mm (0.41 in)
425RS064
2. Measuring the overall length of the pressurering,
friction disc and friction plate.
Mount the pinion shaft in the pressurering and then
install the friction disc & plate.

4A2A–30
DIFFERENTIAL (REAR 220mm)
3. After measuring dimensions of each of the above
sections, proceed with the adjustment in the following
manner:
Adjust the clearance to satisfy the equation below.
{(F – B) + G – H}=0.05 – 0.20 mm
Also, select the thrust washers so that the
dimensional difference between the back surfaces of
the left and right pressure rings to the thrust washers
is 0.05mm or less.
Thickness : 1.5mm (0.059 in)
1.6 mm(0.063 in)
1.7 mm(0.067 in)
NOTE: When assembling the parts, apply recommended
gear oil sufficiently to each of the parts, especially, to the
contact surfaces and sliding surfaces.
1. Install Differential cage B.
2. Install Thrust washer.
3. Install Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct as shown in figure.
425RS068
Legend
(1) Friction Plate
(2) Spring Disc
(3) Friction Disc
4. Inatall Spring disc.
5. Inatall Friction plate.
6. Inatall Friction disc.
7. Inatall Friction plate.
8. Inatall Friction disc.
9. Inatall Pressure ring.
10. Inatall Side gear.
11. Inatall Pinion and pinion shaft.
12. Inatall Side gear.
13. Inatall Pressure ring.
14. Inatall Friction disc.15. Inatall Friction plate.
16. Inatall Friction disc.
17. Inatall Friction plate.
18. Inatall Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct.
19. Inatall Spring disc.
20. Inatall Thrust washer.
21. Inatall Differential cage A.
22. Inatall Screw.
Matching the guide marks of the differential cages A
and B, tighten the screws evenly in the diagonal
order.
425RS055

4A2A–34
DIFFERENTIAL (REAR 220mm)
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2157–0
(J–37221)
Holder; Pinion flange
5–8840–2294–0
(J–24250)
Installer; Oil seal
5–8840–0275–0
(J–37264)
Differential holding
fixture
(Use with
5–8840–0003–0)
5–8840–0003–0
(J–3289–20)
Holding fixture base
5–8840–0013–0
5–8840–0014–0
(J–22888)
Puller; Side bearing
5–8840–2196–0
(J–8107–2)
Adapter; Side bearing
plug
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2197–0
(J–22912–01)
Separator
5–8840–2164–0
(J–24256)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Driver handle
5–8840–2163–0
(J–24252)
Installer; Inner bearing
outer race
5–8840–2085–0
(J–21777–42)
Front Pilot
5–8840–0127–0
(J–23597–9)
Nut and bolt

DIFFERENTIAL (REAR 220mm)
4A2A–35
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2166–0
(J–23597–7)
Gauge plate
5–8840–0126–0
(J–8001)
Dial indicator
5–8840–2167–0
(J–23597–8)
Disc
5–8840–0128–0
(J–23597–1)
Arbor
9–8522–1165–0
(J–6133–01)
Installer; Pinion bearing
5–8840–2293–0
(J–39209)
Punch; End nut lock
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2162–0
(J–24244)
Installer; Side bearing
5–8840–2323–0
(J–39602)
Remover; Outer bearing
5–8840–2165–0
(J–37263)
Installer; Pinion oil seal
5–8840–2381–0
(J–41033)
Holder; Side gear
5–8840–0129–0
(J–23597–12)
Rear pilot

DIFFERENTIAL (REAR 244mm)
4A2B–1
DRIVELINE/AXLE
DIFFERENTIAL (REAR 244mm)
CONTENTS
Service Precaution 4A2B–1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2B–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2B–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2B–4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2B–4. . . . . .
Removal 4A2B–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2B–5. . . . . . . . . . . . . . . . . .
Installation 4A2B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2B–6. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2B–6. . . . .
Removal 4A2B–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–7. . . . . . . . . . . . . . . . . .
Installation 4A2B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A2B–8. . . . . . . . . . . . . . . . . . . .
Differential Assembly and Associated Parts 4A2B–8
Removal 4A2B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A2B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2B–10. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–11. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A2B–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A2B–20. . . . . . . . . . . . . . .
Disassembled View 4A2B–20. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–21. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Locking Differential Assembly 4A2B–23. . . . . . . . . . . . .
Disassembled View 4A2B–23. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–25. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–25. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A2B–27. . . . . . . . . . . . .
Special Tools 4A2B–29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE REFORMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally,such coatings
adversely affect the fastener torque and the joint
c l a m p i n g f o r c e , a n d m a y d a m a g e t h e f a s t e n e r. W h e n
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.

4A2B–4DIFFERENTIAL (REAR 244mm)
Axle Housing
Axle Housing and Associated Parts
420RW001
Legend
(1) Coil Spring and Insulator
(2) Axle Housing Assembly
(3) ABS Speed Sensor and Harness (if so
equipped)
(4) Nut
(5) Parking Brake Cable
(6) Bolt and Nut
(7) Antilock Brake System (ABS) Connector and
Bracket (if so equipped)(8) Bolt and Nut
(9) Nut
(10) Differential Assembly
(11) Axle Shaft Assembly
(12) Brake Disc
(13) Brake Pipe
(14) Brake Caliper
(15) Nut
(16) Breather Hose
(17) Flare Nut
Removal
1. Raise the vehicle and support it with suitable safety
stands.
The hoist must remain under the rear axle housing.
2. Drain brake fluid. Refer to Hydraulic Brakes in Brakes
section.
3. Remove rear wheels and tires. Refer to Wheel in
Suspension section.4. Remove propeller shaft. Refer to Rear Propeller
Shaft in this section.
5. Drain the rear axle oil into a proper container.
6. Remove parking brake cable, release the connection
between the cable fixing clip equalizer. Refer to
Parking Brakes in Brakes section.
7. Move the clip aside and pull out the breather hose.

DIFFERENTIAL (REAR 244mm)
4A2B–5
8. Disconnect the ABS connectors (1) and remove the
brackets (2) (if so equipped) attached to the frame
and center link.
350RS001
9. Loosen the brake tube flare nut, remove the clip and
take out the brake tube.
10. Remove the shock absorber fixing nut from the axle
housing.
11. Remove the stabilizer linkage mounting nut from the
axle housing.
12. Remove the lateral rod fixing nut from the axle
housing.
13. Remove the center link mounting bolt and nut from
the axle housing.
14. Remove the trailing link fixing bolt and nut from the
axle housing.
15. Jack down and remove the coil spring and insulator.
16. Axle housing assembly can be separated from the
vehicle on completion of steps 1 – 11.
17. Remove the brake caliper fixing bolt (3), loosen the
flare nut (1), release the clip (2) and take out the brake
caliper together with the flexible hose.
306RS001
18. Remove brake disc.
19. Remove antilock brake system speed sensor fixing
bolt and the clip and bracket (if so equipped) on the
axle housing.
20. Remove the brake pipe clip and fixing bolt on the axle
housing and take out the brake pipe.
21. Remove the bearing holder fixing nut and take out the
axle shaft assembly, be sure not to damage the oil
seal by the spline of the shaft, Refer to Axle Shaft in
this section.
22. Remove differential assembly, refer to Differential
Assembly in this section.
Oil Seal Replacement
Remove the oil seal, carefully not to damage the housing,
and mount new oil seal using oil seal installer
5–8840–2294–0
420RW028
Installation
1. Install differential assembly, refer to Differential
Assembly in this section.
2. Install axle shaft assembly then tighten the bearing
holder mounting nut to the specified torque. Be sure
not to damage the oil seal by the spline of the shaft.
Torque: 74Nꞏm (7.5kgꞏm/54 lb ft)
3. Install brake pipe.
4. Connect antilock brake system (ABS) speed sensor
and harness (if so equipped), refer to Anti–Lock
Brake System in Brake section.
5. Install brake disc.
6. Install brake caliper. Refer to Disk Brakes in Brake
section.
7. Install axle housing assembly.
8. Install coil spring and insulator.
9. Install the trailing link fixing bolt and nut to the axle
housing. For the procedures in items 9–13, refer to
Suspension section.
10. Install the center link bolt and nut to the axle housing.