1998 OPEL FRONTERA rack

4C–31 DRIVE SHAFT SYSTEM
Sleeve Condition
Check and see that there is no wear, damage, or cracking
in the sleeve.
NOTE: Close inspection of the groove and inner gear are
required because those are important parts.
Sleeve Function
412RW011Operate the sleeve with the inner shaft combined with the
clutch gear. If roughness is felt, replace the sleeve.
NOTE: Gear oil should be applied to the contact surface
of gear.
Check the width of sleeve center groove.
Limit: 7.1 mm (0.28 in) max.
412RW022
Clutch Gear Condition
Check and see that there is no wear, damage, cracking,
or any other abnormality in the clutch gear.
Clutch Gear Function
412RW010If there is an abnormality such as roughness when
operated in combination with sleeve, replace the clutch
gear.
NOTE: When inspecting, gear oil should be applied to the
contact surface of gear.
Clutch Gear Journal Diameter
Make sure of the size illustrated.
Limit: 36.98 mm (1.456 in) min.
412RW009

4C–32
DRIVE SHAFT SYSTEM
Actuator
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
412RW021
412RW013
412RW007Disconnect the shift position switch and make sure of
function with a vacuum of –400 mmHg applied to Ports A
and B, in accordance with the table below.
State
Port APort BFunction
C–400 mmHgA/PE
DA/P–400 mmHgF
If there is an abnormality, replace the actuator as an
assembly.
NOTE:
1. If the actuator works under –400mmHg or less, there
is no functional problem.
2. Be careful not to permit the entry of water or dust into
the ports of the actuator.
Dimensional Check
Measure illustrated sizes 1, 2, and 3.
Limit
1=64.3 mm (2.53 in) max.
2=6.7 mm (0.26 in) min.
3=6.7 mm (0.26 in) min.

4C–34
DRIVE SHAFT SYSTEM
NOTE: Be careful not to damage seal.
6. Install snap ring (internal) in the groove of front axle
case.
NOTE: Be sure to install the snap ring properly.
412RW017
7. Apply differential gear oil to clutch gear, then install
clutch gear.
8. Apply differential gear oil to sleeve, then install
sleeve.
9. Clean contact surface with the front axle and actuator
mounting surface. Apply liquid gasket to the contact
surface on the front axle case, then install in the
housing.
412RW023
10. Tighten bolts to specified torque.
Torque: 116Nꞏm (11.8 kgꞏm/85 lb ft)11. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
Torque: 39Nꞏm (4.0 kgꞏm/29 lb ft)
12. Apply liquid gasket to the contact surface on the
actuator side.
412RW012
13. Align shift arm with the groove of sleeve and install the
actuator.
14. Tighten bolts to specified torque.
Torque: 13Nꞏm (1.3 kgꞏm/113 lb in)
15. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
Torque: 116Nꞏm (11.8 kgꞏm/85 lb ft)
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.4lit (1.23 Imp qt/1.48 US qt)
Actuator Housing
Oil Capacity: 0.12lit (0.10 Imp qt/0.13 US qt)
17. Install filler plug through gasket and tighten to
specified torque.
To r q u e : 7 8 N ꞏm ( 5 8 l b f t )

4C–43 DRIVE SHAFT SYSTEM
Play in Universal Joint
Limit: Less than 0.1 mm (0.004 in)
401RS010
Constant Velocity Joint
NOTE: LJ and BJ constant velocity joints are
unremovable types. Check the joint for play and the boot
for damage, wear, and leak of grease. If abnormality is
found, replace propeller shaft as an assembly.
Play in Constant Velocity Joint
Fix the shaft in a vise throrgh pieces of wood, and try to
move the joint vertically, right and left, and back and forth
to make sure of smooth motions and no remarkable play.
401RW050
401RW049
Boot of Constant Velocity Joint
Check the boot (2) for crack, damage and grease leak,
and the boot band (1) for loosening and damage. Check
the both sides of the joint and make sure that there is no
leak of grease from the cover press-in parts(3).
401RW048

4D1–8
TRANSFER CASE (STANDARD TYPE)
Transfer Rear Oil Seal
Removal
1. Disconnect the rear propeller shaft from the transfer
case side.
2. Remove end nut and rear companion flange, using
the companion flange holder 5–8840–0133–0
(J–8614–11).
266RW026
3. Use the universal puller to remove the rear
companion flange and O–ring.
4. Remove the oil seal from the transfer case.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install oil seal and apply engine oil to the oil seal outer
surfaces.
2. Apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
3. Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear seal to the transfer rear case.
220RW105
4. Install the rear companion flange and O–ring.
5. Use the companion flange holder 5–8840–0133–0
(J–8614–11) to install a new end nut and tighten to the
specified torque.
Torque: 167 Nꞏm (17.0kgꞏm/123 lb ft)
6. Use the punch 5–8840–2293–0 (J–39209) to stake
the end nut at two spots.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the end nut after staking.
266RW027

TRANSFER CASE (STANDARD TYPE)
4D1–15
266RW002
16. Stake the front companion flange nut at one spot.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.
17. Install the O–ring (8) to the speedometer driven gear
bushing (7).
18. Install the driven gear to the speedometer driven gear
bushing (7).
19. Install the speedometer driven gear assembly to the
transfer rear cover.20. Install the plate (6) to the transfer rear case and
tighten to the specified torque.
Torque: 15 Nꞏm (1.5kgꞏm/11 lb ft)
21. Install the speedometer sensor and tighten to the
specified torque.
Torque: 27 Nꞏm (2.8kgꞏm/20 lb ft)
225RW014

TRANSFER CASE (STANDARD TYPE)
4D1–21
5. Install the control box assembly.
Torque: 19 Nꞏm (1.9kgꞏm/14 lb ft)
6. Connect the breather hoses to the control box.
7. Install the rear companion flange and front
companion flange, using the companion flange holder
5–8840–0133–0 (J–8614–11) to tighten the flange
nuts to the transfer case.
262RW067
8. Tighten the new transfer flange nuts to the specified
torque.
Torque
Rear companion flange: 167 Nꞏm (17.0kgꞏm/123
lb ft)
Front companion flange: 137 Nꞏm (14.0kgꞏm/101
lb ft)
9. Use the punch 5–8840–2293–0 (J–39209) to stake
the rear companion flange nut at two spots.
266RW027
266RW002
10. Stake the front companion flange nut at one spot.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.
11. Install the O–ring (8) to the speedometer driven gear
bushing (7).
12. Install the driven gear to the speedometer driven gear
bushing (7).
13. Install the speedometer driven gear assembly to the
transfer rear cover.
14. Install the plate (6) to the transfer rear case and
tighten to the specified torque.
Torque: 15 Nꞏm (1.5kgꞏm/11 lb ft)

4D1–34
TRANSFER CASE (STANDARD TYPE)
2. If the measured value exceeds the specified limit, the
gear must be replaced.
Gear inside diameter
Standard : 48.000–48.013 mm (1.8898–1.8903 in)
Limit : 48.10 mm (1.894 in)
226RS040
Clutch Hub Spline Play
1. Set a dial indicator to the clutch hub to measured.
2. Move the clutch hub as far as possible to both the right
and the left.
Note the dial indicator reading.
3. If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Clutch hub spline play
Standard : 0–0.1 mm (0–0.004 in)
Limit : 0.2 mm (0.008 in)
226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)
226RS043
Synchronizers
The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
Teeth for wear, scuffs, nicks, burrs or breaks.
Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace the
component.
Block Ring and Insert Clearance
1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limit, the
block ring and the insert must be replaced.
Block ring and insert clearance
Standard : 2.46–2.74 mm (0.097–0.108 in)