1998 OPEL FRONTERA Differential oil

DIFFERENTIAL (REAR 244mm)
4A2B–21
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin using a small drift.
425RS042
4. Remove the differential shaft by using a hard metal
rod and a hammer.
425RS043
5. Remove pinion mate gear and thrust washer.
6. Remove side gear and thrust washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
Ring gear, pinion gear
Bearing
Side gear, pinion mate gear, differential shaft
Differential cage, carrier
Thrust washer
Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
3. Tighten the fixing bolts in a diagonal sequence as
illustrated.
Torque: 177Nꞏm (18.0kgꞏm/130 lb ft)
425RW033
Reassembly
425RS048
1. Install side gear with thrust washer.

DIFFERENTIAL (REAR 244mm)
4A2B–29
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2294–0
(J–39210)
Installer; Axle shaft inner
seal
5–8840–0133–0
(J–8614–01)
Pinion flange holder
5–8840–2165–0
(J–37263)
Installer; Pinion oil seal
5–8840–2029–0
(J–42832)
Holding fixture
5–8840–0003–0
(J–3289–20)
Holding fixture base
5–8840–2587–0
(J–42379)
Remover; Bearing
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2576–0
(J–8107–3)
Adapter; Side bearing
plug
5–8840–0008–0
(J–8611–01)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Grip
5–8840–2571–0
(J–42831)
Installer; Inner bearing
outer race
5–8840–2575–0
(J–42824)
Pilot;Outer
5–8840–0127–0
(J–21777–43)
Nut & Stud

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–88
StepActionYe sNo
1Are the front and rear tires in specified size?
Go to Step 2
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
2Is the tire pressure correct?
Go to Step 3
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
3Are the tires free from abnormal wear?
Go to Step 4
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
4Are different types of tires used?
Go to Step 5
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
51. Start the engine.
2. Shift the transfer lever to the high (TOD) position.
3. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 6 Go to Step 11
61. Shift the transfer lever to the 2H position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 7 Go to Step 14
7Is an LSD mounted to the rear differential? Go to Step 8 Go to Step 9
8Is the genuine LSD oil used in the rear differential?
Go to Step 9
Replace the
differential oil.
Go to Step 16
9Does the engine output the power correctly?
Go to Step 10
Check the
engine.
Go to Step 16
10Do the speed sensors work correctly? (Check trouble codes.)The ECU has
failed. Replace
the ECU.
Go to Step 16
Replace the
speed sensors.
Go to Step 16
11Is the tight corner braking observed only when the brake is
applied?
Go to Step 12
Conduct full
steering under
WOT.
Go to Step 5
121. Turn off the starter switch.
2. Disconnect the ECU connector.
Is the battery voltage observed between terminals (B–68)6 and
(B–67)11?
Go to Step 13
Repair the circuit
of terminal 6
(ABS IN).
Go to Step 16

4C–3 DRIVE SHAFT SYSTEM
Diagnosis
ConditionPossible causeCorrection
Oil Leak At Front AxleWorn or defective oil seal.Replace the oil seal.
Front axle housing cracked.Repair or replace.
Oil Leak At Pinion ShaftToo much gear oil.Correct the oil level.
Oil seal worn or defective.Replace the oil seal.
Pinion flange loose or damaged.Tighten or replace.
Noises In Front Axle Drive Shaft
JointBroken or worn drive shaft joints and
bellows (BJ and DOJ).Replace the drive shaft joints and
bellows.
“Clank” When Accelerating From
“Coast”Loose drive shaft joint to output shaft
bolts.Tighten.
Damaged inner drive shaft joint.Replace.
Shudder or Vibration During
Acceleration
Excessive drive shaft joint angle.Repair.
AccelerationWorn or damaged drive shaft joints.Replace.
Sticking spider assembly (inner drive
shaft joint).Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint).Lubricate or replace.
Vibration At Highway SpeedsOut of balance or out of round tires.Balance or replace.
Front end out of alignment.Align.
Noises in Front AxleInsufficient gear oil.Replenish the gear oil.
Wrong or poor grade gear oil.Replace the gear oil.
Drive pinion to ring gear backlash
incorrect.Adjust the backlash.
Worn or chipped ring gear, pinion
gear or side gear.Replace the ring gear, pinion gear or
side gear.
Pinion shaft bearing worn.Replace the pinion shaft bearing.
Wheel bearing worn.Replace the wheel bearing.
Differential bearing loose or worn.Tighten or replace.
Wanders and PullsWheel bearing preload too tight.Adjust the wheel bearing preload.
Incorrect front alignment.Adjust the front alignment.
Steering linkage loose or worn.Tighten or replace.
Steering gear out of adjustment.Adjust or replace the steering gear.
Tire worn or improperly inflated.Adjust the inflation or replace.
Front or rear suspension parts loose
or broken.Tighten or replace.
Front Wheel ShimmyWheel bearing worn or improperly
adjusted.Adjust or replace.
Incorrect front alignment.Adjust the front alignment.
Worn ball joint or bush.Replace the ball joint or bush.
Steering linkage loose or worn.Tighten or replace.
Steering gear out of adjustment.Tighten or replace.
Tire worn or improperly inflated.Replace or adjust the inflation.
Shock absorber worn.Replace the shock absorber.

4C–23 DRIVE SHAFT SYSTEM
Front Axle Drive Shaft
Front Axle Drive Shaft and Associated Parts
This illustration is based on the model equipped with shift on the fly system.
412RW003
Legend
(1) Axle Case and Differential
(2) DOJ Case Assembly
(3) Snap Ring
(4) Bearing
(5) Snap Ring
(6) Oil Seal
(7) Bracket
(8) DOJ Case
(9) Circlip
(10) Bolt
(11) Drive Shaft Joint Assembly
(12) Snap Ring(13) Spacer
(14) Ball
(15) Snap Ring
(16) Ball Retainer
(17) Ball Guide
(18) Band
(19) Bellows
(20) Band
(21) Band
(22) Bellows
(23) Band
(24) BJ Shaft
(25) Dust Seal

4C–33 DRIVE SHAFT SYSTEM
412RS037
Reassembly
1. Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer
5–8840–2407–0 and grip 5–8840–0007–0.
412RS043
2. Force a new needle bearing into inner shaft by using a
installer 5–8840–2408–0 and grip 5–8840–0007–0.
412RS051
3. Place a new snap ring(internal) in inner shaft.
Force a new inner shaft bearing into the inner shaft by
using a installer 5–8840–2197–0 and press.
412RS044
4. Install snap ring(external).
NOTE: Be careful not to damage the inner shaft.
5. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.

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–35 DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
Front drive axle oil capacity1.4 liter (1.23 Imp qt/1.48 US qt)(Differential)
0.12 liter (0.10 Imp qt/0.13 US qt)(Actuator Housing:Shift on the fly)
Type of lubricantGL–5 (Multi grade type) Refer to chart in General Information
Axle shaft typeConstant velocity joint(Birfield joint type and double offset joint)
Torque Specifications
E04RW020