1998 OPEL FRONTERA Workshop Manual

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Page 665 of 6000

OPEL FRONTERA 1998 Workshop Manual DRIVE LINE CONTROL SYSTEM (TOD) 4B2–94
Chart 4The braking distance gets long even when the ABS is active.
Function of circuit—
Fail conditionEnough deceleration is not obtained and the braking dis

Page 666 of 6000

OPEL FRONTERA 1998 Workshop Manual DRIVE LINE CONTROL SYSTEM (TOD) 4B2–95
Step Action Yes No
1 Are the brake and ABS systems healthy?
Go to Step 2Repair the
brake and ABS.
Go to Step 4
2 Turn on the starter switch.
Is the battery

Page 667 of 6000

OPEL FRONTERA 1998 Workshop Manual 4C–1 DRIVE SHAFT SYSTEM
DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution 4C–2. . . . . . . . . . . . . . . . . . . . . .
General Description 4C–2. . . . . . . . . . . . . . . . . .

4C–1 DRIVE SHAFT SYSTEM
DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution 4C–2. . . . . . . . . . . . . . . . . . . . . .
General Description 4C–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4C–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Shaft 4C–4. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Shaft and Associated Parts 4C–4. . . .
Removal 4C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4C–5. . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4C–6. . . . . . . . . . . . . . . . . .
Installation 4C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 4C–8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc (with Shift on the Fly) 4C–9. .
Disassembled View 4C–9. . . . . . . . . . . . . . . . . . . .
Disassembly 4C–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4C–10. . . . . . . . . . . . . . . . . .
Reassembly 4C–11. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc with Manual Locking Hub 4C–14
Disassembled View 4C–14. . . . . . . . . . . . . . . . . . . .
Disassembly 4C–14. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4C–16. . . . . . . . . . . . . . . . . .
Reassembly 4C–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4C–20. . . . . . . . . . . . .
Special Tools 4C–21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joint 4C–22. . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joints Replacement 4C–22. . . .
Front Axle Drive Shaft 4C–23. . . . . . . . . . . . . . . . . . .
Front Axle Drive Shaft and Associated
Parts 4C–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 4C–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4C–25. . . . . . . . . . . . . . . . . .
Bushing Replacement 4C–25. . . . . . . . . . . . . . . . . . Reassembly 4C–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Shift On The Fly System 4C–28. . . . . . . . . . . . . . . . .
Shift On The Fly System and Associated
Parts 4C–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 4C–28. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4C–30. . . . . . . . . . . . . . . . . .
Main Data and Specifications 4C–35. . . . . . . . . . .
Special Tools 4C–36. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft 4C–37. . . . . . . . . . . . . . . . . . . . .
General Description 4C–37. . . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft and Associated Parts 4C–38
Removal 4C–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4C–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly (Except TOD 4
4) 4C–40. . . . . . . . .
Universal Joint Disassembly 4C–41. . . . . . . . . . . .
Inspection and Repair 4C–42. . . . . . . . . . . . . . . . . .
Universal Joint Reassembly 4C–45. . . . . . . . . . . . .
Reassembly (Except TOD 4
4) 4C–46. . . . . . . . . .
Main Data and Specifications 4C–47. . . . . . . . . . .
Rear Propeller Shaft 4C–48. . . . . . . . . . . . . . . . . . . . .
General Description 4C–48. . . . . . . . . . . . . . . . . . . . .
Rear Propeller Shaft and Associated Parts 4C–48
Removal 4C–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4C–49. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 4C–50. . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Joint Disassembly 4C–51. . . . . . . . . . . .
Inspection and Repair 4C–52. . . . . . . . . . . . . . . . . .
Universal Joint Reassembly 4C–53. . . . . . . . . . . . .
Reassembly 4C–54. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4C–55. . . . . . . . . . .

Page 668 of 6000

OPEL FRONTERA 1998 Workshop Manual 4C–2
DRIVE SHAFT SYSTEM
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

Page 669 of 6000

OPEL FRONTERA 1998 Workshop Manual 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 P

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.

Page 670 of 6000

OPEL FRONTERA 1998 Workshop Manual 4C–4
DRIVE SHAFT SYSTEM
Rear Axle Shaft
Rear Axle Shaft and Associated Parts
420RW014
Legend
(1) Brake Caliper
(2) Brake Disc
(3) Wheel Pin
(4) Axle Shaft Assembly
(5) Back Plate
(6) Parking Brake A

Page 671 of 6000

OPEL FRONTERA 1998 Workshop Manual 4C–5 DRIVE SHAFT SYSTEM
7.Remove the parking brake cable mounting
bolts(Behind the back plate)(1).
311RS001
8. Remove the bearing holder mounting nuts.
9. Remove axle shaft assembly.
NOTE: Be sure n

Page 672 of 6000

OPEL FRONTERA 1998 Workshop Manual 4C–6
DRIVE SHAFT SYSTEM
Axle Shaft Run–out
Limit: 1.0 mm (0.039 in)
420RW025
Axle Shaft Flange Run–out
Limit: 0.08 mm (0.003 in)
420RS010
Oil Seal Replacement
Remove the oil seal carefully not t

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