OPEL FRONTERA 1998 Workshop Manual

4A2A–22
DIFFERENTIAL (REAR 220mm)
17. Tighten the cap bolt to the specified torque.
Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft)
425RS036
1. Measure the amount of run–out of the ring gear at
its rear face.
Standard: 0.02 mm ( 0.001 in)
Limit: 0.05 mm ( 0.002 in)
425RS037
Gear Tooth Contact Pattern Check and Adjustment
1. Apply a thin coat of prussian blue or equivalent
to the faces of the 7–8 teeth of the ring gear.
Check the impression of contact on the ring
gear teeth and make necessary adjustment as
described in illustration if the contact is
abnormal.
425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)

DIFFERENTIAL (REAR 220mm)
4A2A–23
425RS039

4A2A–24
DIFFERENTIAL (REAR 220mm)
Differential Cage Assembly
Disassembled View
415RW034
Legend
(1) Pinion Gear
(2) Thrust Washer
(3) Side Gear
(4) Cross Pin(5) Ring Gear
(6) Bolt
(7) Differential Cage
(8) Lock Pin
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin, break staking on the lock pin, using
a 5 mm (0.20 in) diameter drill.
425RS042

DIFFERENTIAL (REAR 220mm)
4A2A–25
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 (11.0kgꞏm/80 lb ft)5. Tighten the fixing bolts in a diagonal sequence as
illustrated.
415RW036
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

4A2A–26
DIFFERENTIAL (REAR 220mm)
Clearance between the side gear and the
differential box:
Standard: 0.05–0.12 mm (0.002–0.005 in)
Limit: 0.15 mm(0.006 in)
425RS046
Legend
(1) Side Gear
(2) Differential Box
Play in splines between the side gear and
the axle shaft:
Standard: 0.07–0.38 mm(0.003 –0.014 in)
Limit:0.5m (0.02 in)
425RS047
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.
425RS048
4. Install cross pin.
1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
2. Adjust the backlash between the side gear and
the pinion gear.
Backlash:0.13 – 0.18 mm (0.005– 0.007 in)

DIFFERENTIAL (REAR 220mm)
4A2A–27
Thickness of thrust washers available:
0.80 mm, 0.90 mm, 1.00 mm 1.10 mm, 1.20 mm,
1.30 mm (0.031 in, 0.035 in, 0.039 in,0.043 in,
0.047 in, 0.051 in)
425RS050
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
425RS051
Legend
(1) Staked Portion
(2) Lock Pin
6. Clean the ring gear threaded holes to remove the
locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.7. Tighten the bolts in diagonal sequence as illustrated.
Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft)
NOTE: Discard used bolts and install new ones.
415RW036

4A2A–28
DIFFERENTIAL (REAR 220mm)
Limited Slip Differential
Disassembled View
425RY001
Legend
(1) Screw
(2) Differential cage A
(3) Thrust washer
(4) Spring disc
(5) Friction Plate
(6) Friction plate
(7) Friction Plate
(8) Friction disc
(9) Friction Plate
(10) Friction disc
(11) Friction Plate
(12) Pressure ring
(13) Side gear(14) Pinion and Pinion shaft
(15) Side gear
(16) Pressure ring
(17) Friction Plate
(18) Friction disc
(19) Friction Plate
(20) Friction disc
(21) Friction Plate
(22) Friction Plate
(23) Friction Plate
(24) Spring disc
(25) Thrust washer
(26) Differential cage B

DIFFERENTIAL (REAR 220mm)
4A2A–29
Disassembly
Differential Cages A and B
1. To ensure installation of the parts in original position
apply a setting mark before removing the differential
cages A and B.
2. Using special tool, 5–8840–2682–0, grip it with a vice,
and set the differential.
425RS054
3. Gradually and evenly loosen the 3 fixing screws of the
differential cages A and B.
425RS055
4. Remove Differential cage A.
5. Remove Thrust washer.
6. Remove Spring disc.
NOTE: When removing the spring disc, friction disc, and
friction plate, place them in order for clear distinction of
left and right use.
7. Remove Spring disc.
8. Remove Friction plate.9. Remove Friction plate.
10. Remove Friction disc.
11. Remove Friction plate.
12. Remove Friction disc.
13. Remove Friction plate.
14. Remove Pressure ring.
15. Remove Side gear.
16. Remove Pinion and pinion shaft.
17. Remove Side gear.
18. Remove Pressure ring.
19. Remove Friction plate.
20. Remove Friction disc.
21. Remove Friction plate.
22. Remove Friction disc.
23. Remove Friction plate.
24. Remove Friction plate.
25. Remove Friction plate.
26. Remove Friction disc.
27. Remove Thrust washer.
28. Remove Differential cage B.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
Visual check
Check the following parts for wear, damage, noise or any
other abnormal conditions.
Friction disc, friction plate and spring disc
425RS056
Legend
(1) Sliding surfaces
(2) Projections

4A2A–30
DIFFERENTIAL (REAR 220mm)
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 220mm)
4A2A–31
Measure the Deformation of the friction disc & plate.
Limit: 0.1 mm (0.004 in)
425RS061
Measure the wear of the friction plate & disc
Limit(A–B): 0.1 mm (0.004 in)
Remarks:
A=Inner or outer projections
B=Sliding surface subjected to abrasion
425RS062
Measure the wear of the thrust washer
Limit: 1.3 mm (0.05 in)
425RS063
Reassembly
Adjust the clearance between the friction disc and plate.
1. Measuring the depth of the differential cage.
Standard (A–B): 89.13 mm (3.51 in)
(C): 9.13 mm (0.36 in)
425RS064