1998 OPEL FRONTERA oil

DIFFERENTIAL (REAR 244mm)
4A2B–25
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin using a small drift.
425RY00002
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. Clean the ring gear threaded holes to remove the
locking argent.
3. Discard used bolts and install new ones.
4. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and ha of the
unthreaded area of the bolt.
Torque: 127Nꞏm (13.0kgꞏm/94 lb ft)
425RW033Clearance between the differential pinion and the
pinion shaft measurement.
Standard: 0.07 – 0.13 mm (0.003 – 0.005 in)
Limit: 0.2 mm (0.008 in)
425RY00007

4A2B–30DIFFERENTIAL (REAR 244mm)
Pressure ring
425RY003
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
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.

DIFFERENTIAL (REAR 244mm)
4A2B–33
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.
425RY004
Legend
(1) Friction Plate
(2) Spring Disc
(3) Friction Disc
4. Install Friction disc.
5. Install Friction plate.6. Install Friction plate.
7. Install Friction disc.
8. Install Friction plate.
9. Install Friction disc.
10. Install Friction plate.
11. Install Pressure ring.
12. Install Side gear.
13. Install Pinion and pinion shaft.
14. Install Side gear.
15. Install Pressure ring.
16. Install Friction plate.
17. Install Friction disc.
18. Install Friction plate.
19. Install Friction disc.
20. Install Friction plate.
21. Install Friction plate.
22. Install Friction plate.
23. Install Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct.
24. Install Spring disc.
25. Install Thrust washer.
26. Install Differential cage A.
27. Install Screw.
Matching the guide marks of the differential cages A
and B, tighten the screws evenly in the diagonal
order.
425RS055

DIFFERENTIAL (REAR 244mm)
4A2B–37
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
5–8840–2689–0
(J–44461)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Grip
5–8840–2690–0
(J–44462)
Installer; Inner bearing
outer race
5–8840–2681–0
(J–42824)
Pilot;Outer
5–8840–0127–0
(J–21777–43)
Nut & Bolt

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–2
General Description
C07RW014–1
TOD (Torque on Demand) system is traction state control
system to vehicle.
Transfer Position and Drive Mode
Three drive modes can be selected through operation of
4WD AUTO switch and transfer lever.
Transfer Position
4WD AUTO SWModeDrive mode
HIGHON (NORMAL)2HRear wheel drive
OFF (PUSHED)TODElectronically controlled torque split
four wheel drive
4LON/OFF4LLow-speed mechanical lock-up four
wheel drive
The electronic control unit (ECU) judges the signals from
the transfer lever and 4WD AUTO switch, and controls
the transfer drive mode and shift-on-the-fly system
status.
TOD Control
The TOD position usually drives the rear wheels, and
transmits the torque to the front wheels with the help of
electronically controlled torque split mechanism
according to running conditions encountered. The driving
force is directly transmitted to the rear wheels. This force
is split by the transfer and delivered to the front wheels.
The magnitude of the torque transmitted to the front
wheels is controlled by changing the pressing force of the
multi plate disk clutch built in the transfer unit. Thepressing force of the clutch is controlled by changing the
duty cycle to the electromagnetic coil mounted to the rear
of the clutch. When the clutch is completely disengaged,
the rear wheels are driven. When the clutch is completely
engaged, a rigid four wheel drive mode is obtained. The
torque split status is controlled continuously between the
rear wheel and four wheel drive modes. This system
includes front and rear speed sensors, and receives
throttle position sensor information from ECM.
The control unit receives signals sent from these sensors
and changes the pressing force of the multi plate disk
clutch to determine the torque distribution on the front and
rear wheels. Therefore, when the slip of the rear wheels is
increased against the current torque level in the normal
rear wheel drive mode, the control unit detects the slip

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–4
System Components
Parts Location
A07RY00002
Legend
(1) T/F Connector
(2) 4H and 4L Switch
(3) High-Low Planetary Gear Set
(4) Mechanical Lock(5) Multi Plate Disk Clutch Pack
(6) Electromagnetic Coil
(7) Rear Speed Sensor
(8) Front Speed Sensor

4B2–5 DRIVE LINE CONTROL SYSTEM (TOD)
Front and Rear Speed Sensors
The sensors are built in the transfer case, detect the
rotation of rotors directly coupled to the propeller shafts.
Thirty rectangular pulses are output per one rotation of
the propeller shaft.
261RW045
Electromagnetic Coil
Receives the duty signals from the TOD control unit and
controls the pressing force of the clutch pressure cam.
261RW044
Multi Plate Disk Clutch Pack
Transmits the torque determined by the clutch pressing
force to the front propeller shaft via the front drive chain.
262RW029
Mechanical Lock Sleeve
Couples the front and rear propeller shaft mechanically
when the transfer shaft is in the 4L position.
262RW028

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–6
High-Low Planetary Gear Set
Establishes an auxiliary transmission mechanism. When
the transfer shift lever is set to the 2H or TOD position, the
reduction gear ratio is 1.000 and the corresponding
driving force is generated. When the transfer shift lever is
set to the 4L position, the reduction gear ratio is 2.480 and
the corresponding driving force is generated.
262RW030
4H and 4L Switch
Detects the shift position of the transfer from the
movement of the transfer lever and outputs signals to the
TOD control unit.
261RW002
Transfer Connector
Transmits the input and output signals of the speed
sensors, electromagnetic coil, and 4H and 4L switche to
the vehicle harness. A waterproof 12-pin type is used.
261RW046
TOD Indicator Lamps (on the instrument
panel)
Inform the following items.
Bulb check
Drive mode
ABS IN status
BRAKE ON status
821RW049