OPEL FRONTERA 1998 Workshop Manual

4A2A–32
DIFFERENTIAL (REAR 220mm)
2. Measuring the overall length of the pressurering,
friction disc and friction plate.
Mount the pinion shaft in the pressurering and then
install the friction disc & plate.
Measure the length between the plates over the
V–groove. (D)
425RS065
3. After measuring dimensions A,B,C and D, make
adjustment in the following manner:
Measure the thickness (E) of the spring disc.
1.75mm (0.069in)
2discs
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness
:1.65–1.75–1.85mm(0.065–0.069–0.073 in)
Backlash adjustment of the side gear in
the direction of the shaft
1. Measuring the depth of the differential cage.
(F–B): 95.63 mm (3.76 in)
(G): 15.63 mm (0.62 in)
425RS066
2. Measuring the dimension between the thrust washers
at both ends.
Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.
Have the side gear contact to the pinion to make the
backlash 0.
Measure the dimension (H) between thrust
washers at both ends.
425RS067

DIFFERENTIAL (REAR 220mm)
4A2A–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

4A2A–34
DIFFERENTIAL (REAR 220mm)
28. Check the operation.
Measure the starting torque using the side gear
holder.
Starting torque:
29–45Nꞏm(3.0–4.6kgꞏm/22–33Ibft)
425RW065
Legend
(1) Side Gear Holder : 5–8840–2381–0

DIFFERENTIAL (REAR 220mm)
4A2A–35
Main Data and Specifications
General Specifications
Rear axle
Ty p eBanjo, Semi–floating
Rear axle Size220mm(8.66in)
Gear typeHypoid
Gear ratio (to 1)4.555(6VD1,4JG2–TC)
4.777(4JG2)
Differential typePinion (STD), Four pinion (LSD)
Lubricant GradeGL–5: (Standard differential)
GL–5, LSD: (Limited slip differential)
Locking Differential Lubricant80W90 GL–5 Limited Slip Differential Gear Lubricant
together with Limited Slip Differential Lubricant Additive
(Part No. 8–01052–358–0) or equivalent.
Capacity1.8liter(1.6 Imp qt/1.9 US qt)

4A2A–36
DIFFERENTIAL (REAR 220mm)
Torque Specifications
420RY00008

DIFFERENTIAL (REAR 220mm)
4A2A–37
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2157–0
(J–37221)
Holder; Pinion flange
5–8840–2294–0
(J–24250)
Installer; Oil seal
5–8840–0275–0
(J–37264)
Differential holding
fixture
(Use with
5–8840–0003–0)
5–8840–0003–0
(J–3289–20)
Holding fixture base
5–8840–0013–0
5–8840–0014–0
(J–22888)
Puller; Side bearing
5–8840–2196–0
(J–8107–2)
Adapter; Side bearing
plug
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2197–0
(J–22912–01)
Separator
5–8840–2164–0
(J–24256)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Driver handle
5–8840–2163–0
(J–24252)
Installer; Inner bearing
outer race
5–8840–2085–0
(J–21777–42)
Front Pilot
5–8840–0127–0
(J–23597–9)
Nut and bolt

4A2A–38
DIFFERENTIAL (REAR 220mm)
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2166–0
(J–23597–7)
Gauge plate
5–8840–0126–0
(J–8001)
Dial indicator
5–8840–2167–0
(J–23597–8)
Disc
5–8840–0128–0
(J–23597–1)
Arbor
9–8522–1165–0
(J–6133–01)
Installer; Pinion bearing
5–8840–2293–0
(J–39209)
Punch; End nut lock
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2162–0
(J–24244)
Installer; Side bearing
5–8840–2323–0
(J–39602)
Remover; Outer bearing
5–8840–2165–0
(J–37263)
Installer; Pinion oil seal
5–8840–2682–0
(J–44450)
Holder; Side gear
5–8840–0129–0
(J–23597–12)
Rear pilot

DIFFERENTIAL (REAR 244mm)
4A2B–1
DRIVELINE/AXLE
DIFFERENTIAL (REAR 244mm)
CONTENTS
Service Precaution 4A2B–1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2B–3. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2B–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2B–5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2B–5. . . . . .
Removal 4A2B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2B–6. . . . . . . . . . . . . . . . . .
Installation 4A2B–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shaft 4A2B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shaft and Associated Parts 4A2B–7. . . . . . . . .
Removal 4A2B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–8. . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2B–9. . . . . . . . . . . . . . . . . .
Installation 4A2B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2B–10. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2B–10. . . . .
Removal 4A2B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–11. . . . . . . . . . . . . . . . . .
Installation 4A2B–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Assembly 4A2B–12. . . . . . . . . . . . . . . . . . . .
Differential Assembly and Associated Parts 4A2B–12
Removal 4A2B–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A2B–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2B–14. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–15. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A2B–17. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A2B–24. . . . . . . . . . . . . . .
Disassembled View 4A2B–24. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–25. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–25. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Slip Differential 4A2B–28. . . . . . . . . . . . . . . . . . .
Disassembled View 4A2B–28. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–29. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–29. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–31. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A2B–35. . . . . . . . . . . . .
Special Tools 4A2B–37. . . . . . . . . . . . . . . . . . . . . . . . . . .
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
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE REFORMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally,such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.
The
244 differential has two N types A-type and B-
type.
A-type: the sticker with bar code is attached.
B-type: the sticker with no bar code on the lower part
of carrier is attached.

4A2B–2DIFFERENTIAL (REAR 244mm)
In case of Work Shop Manual;
A-type: Refer to ’98 UBS Work Shop Manual.
B-type: Described in ’00UBS Work Shop Manual.
425RY00018

DIFFERENTIAL (REAR 244mm)
4A2B–3
General Description
The rear axle assembly is of the semi–floating type in
which the vehicle weight is carried on the axle housing .
The center line of the pinion gear is below the center line
of the ring gear (hypoid drive).
All parts necessary to transmit power from the propeller
shaft to the rear wheels are enclosed in a banjo type axle
housing.
The 9.61 inch ring gear rear axle uses a conventional ring
and pinion gear set to transmit the driving force of the
engine to the rear wheels. This gear set transfers thisdriving force at a 90 degree angle from the propeller shaft
to the drive shafts.
The axle shafts are supported at the wheel end of the
shaft by a roller bearing.
The pinion gear is supported by two tapered roller
bearings. The pinion depth is set by a shim pack located
between the gear end of the pinion and the roller bearing
that is pressed onto the pinion. The pinion bearing
preload is set by crushing a collapsible spacer between
the bearings in the axle housing.
420RY00006
The ring gear is bolted onto the differential cage with 12
bolts.
The differential cage is supported in the axle housing by
two tapered roller bearings. The differential and ring gear
are located in relationship to the pinion by using selective
shims and spacers between the bearing and the axle
housing. To move the ring gear, shims are deleted from
one side and an equal amount are added to the other side.
These shims are also used to preload the bearings whichare pressed onto the differential cage. Two bearing caps
are used to hold the differential into the rear axle housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues to
transmit the driving force. This prevents tire scuffing
when going around corners and prevents premature wear
on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at each
axle shaft end, and by a liquid gasket between the
differential carrier and the axle housing.