1998 OPEL FRONTERA oil

DIFFERENTIAL (FRONT) 4A1–4
3. Remove the front propeller shaft. Refer to Front
Propeller Shaft in this section.
4. Remove flange nut by using pinion flange holder
5–8840–2157–0.
425RW045
5. Remove flange.
6. Remove oil seal.
7. Remove outer bearing by using remover
5–8840–2323–0.
415RW022
8. Remove collapsible spacer.
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:
1. Seal surface of the pinion.
2. Cage bore for burns.
Installation
1. Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
2. Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.
3. Install oil seal, use oil seal installer 9–8522–1275–0 to
install a new oil seal that has been soaked in axle
lubricant.
415RW021
4. Install flange.
5. Install flange nut, refer to Differential Assembly for
flange nut reassembly in this section.
NOTE: Discard the used nut and install a new one.

DIFFERENTIAL (FRONT) 4A1–6
3. Remove the drain bolt to drain differential oil.
NOTE:
a. During the work, be sure that the diff case is
supported by the jack.
412RS003
b. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Front Disc Brake Caliper Assembly
in Brake section.
c. Remove the antilock brake system speed sensor (if
equipped). Refer to Front Wheel Speed Sensor in
Brakes section.
4. Remove the hub assembly (Disc, back plate and
knuckle), refer to Front Hub and Disc in this section.
5. Disconnect the knuckle and the suspension arm.
Refer to Suspension section.
6. Remove steering link and arm assembly, refer to
Steering Linkage in Steering section.
7. Remove suspension crossmember.
8. Remove propeller shaft, refer to Front Propeller Shaft
in this section.
9. Remove protector (Shift on the fly model).
10. Remove the hose clip.
11. Disconnect breather hose from front drive axle tube.
(and disconnect housing : Shift on the fly model).
12. Disconnect vacuum hose from actuator (Shift on the
fly model).13. Disconnect shift switch connector (Shift on the fly
model).
412RS031
14. Remove VSV assembly (1) (Shift on the fly model).
NOTE: Be sure not to remove hose and connector from
VSV asm.
412RW002

4A1–9 DIFFERENTIAL (FRONT)
Differential Assembly
Disassembled View
415RW001
Legend
(1) Differential Assembly
(2) Flange Nut
(3) Flange
(4) Dust Cover
(5) Oil Seal
(6) Outer Bearing
(7) Outer Bearing Outer Race
(8) Damper
(9) Bracket
(10) Differential Carrier
(11) Bearing Cap(12) Bolt
(13) Inner Bearing Outer Race
(14) Collapsible Spacer
(15) Pinion Gear
(16) Inner Bearing
(17) Adjust Shim
(18) Diff Cage Assembly
(19) Side Bearing Outer Race
(20) Side Bearing
(21) Adjust Shim
(22) Bolt
(23) Axle Case

4A1–11 DIFFERENTIAL (FRONT)
12. Remove dust cover.
13. Remove the drive pinion assembly using a soft metal
rod and a hammer.
425RW041
14. Remove collapsible spacer.
15. Remove the inner bearing using a separator
5–8840–0015–0 and a press.
415RW033
16. Remove adjust shim.
17. Remove inner bearing outer race.
18. Remove oil seal.
19. Remove outer bearing.20. Remove the inner bearing outer race (1) and the outer
bearing outer race (2) by using a brass bar and a
hammer.
425RS014
425RS015

DIFFERENTIAL (FRONT) 4A1–12
21. Remove damper and bracket.
425RW042
Reassembly
1. Using installer 9–8522–1141–0 and grip
5–8840–0007–0, install outer bearing outer race.
415RW018
2. Using installer 9–8522–1274–0 and grip
5–8840–0007–0, install Inner bearing outer race.
415RW017
3. Install adjust shim and adjust drive pinion mounting
distance
1. Apply gear oil to the inner and outer drive pinion
bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the inner
and outer bearings.
2. Tighten the nut to the specified torque.
Torque: 2.3 Nꞏm (0.23kgꞏm/20 lb in)
415RS009
Legend
(1) Pilot : 5–8840–2085–0
(2) Nut and Bolt : 5–8840–2089–0
(3) Gauge Plate : 5–8840–2087–0

DIFFERENTIAL (FRONT) 4A1–16
NOTE: Do not apply pressure to the roller cage and apply
pressure only to the inner race.
425RW048
5. Discard the used collapsible spacer and install a new
one.
6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer 9–8522–1275–0 to install a new
oil seal that has been soaked in rear axle lubricant.
NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.
415RW024
9. Install dust cover.
10. Install flange.
11. Install flange nut.
1. Apply lubricant to the pinion threads.
2. Tighten the nut to the specified torque using the
pinion flange holder 5–8840–2157–0.
Torque: 177–275Nꞏm (18–28kgꞏm/130–203 lb ft)NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
425RW047
3. Adjust pinion bearing preload.
a. Measure the bearing preload by using a torque
meter. Note the scale reading required to
rotate the flange.
b. Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing
0.7–1.1 Nꞏm(0.065–0.115kgꞏm/5.64–9.98 lb in)
Used bearing
0.4–0.5Nꞏm(0.033–0.057kgꞏm/2.86–4.94 Ib in)
425RS027
4. Using punch 5-8840-2293-0, stake the flange nut
at two points.

DIFFERENTIAL (FRONT) 4A1–22
4. Remove the cross pin, using a soft metal rod and a
hammer.
425RS043
5. Remove pinion gear.
6. Remove side gear.
7. Remove 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:
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Clean the ring gear threaded holes to remove the
locking agent.
3. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt.
4. Discard used bolts and install new ones.
Torque: 108 Nꞏm (11kgꞏm/80 lb ft)5. Tighten the fixing bolts in a diagonal sequence as
illustrated.
415RS016
Clearance between the differential pinion
and the cross pin measurement:
Standard: 0.06 – 0.12 mm (0.002–0.005 in)
Limit: 0.2 mm (0.008 in)
425RS045

4A1–25 DIFFERENTIAL (FRONT)
Main Data and Specifications
General Specifications
Axle tube TypeIt consists of the duct, a cast iron housing and the axle
tube.
Gear typeHypoid
Gear ratio(to 1)4.100(6VE1)
4.300(4JX1, 6VE1)
4.555(4JG2–TC, 6VD1)
4.777(4JG2)
Differential typeTwo pinion
Oil capacityliter (Imp qt/US
qt)1.4 (1.2/1.5) (Differential)
0.12 (0.11/0.13) (Actuator Housing: Shift on the fly)
Type of lubricant75W–90 GL–5 (Multi grade type)
Refer to General Information
Axle shaft typeConstant velocity joint
(Birfield joint type and double offset joint)