ABS OPEL FRONTERA 1998 User Guide

4A2B–8DIFFERENTIAL (REAR 244mm)
Differential Assembly
Differential Assembly and Associated Parts
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Legend
(1) Bolt and Nut
(2) Axle Shaft Assembly(3) Parking Brake Cable
(4) Differential Assembly
(5) Nut
Removal
1. Jack up and support the frame with stands.
2. Remove the wheel and tire. Refer to Wheel in
Steering section.
3. Drain the differential oil.
4. Remove the propeller shaft. Refer to Rear Propeller
Shaft in this section.
5. Remove the ABS speed sensor. Refer to Anti–lock
Brake System in Brakes section.6. Remove the parking brake cable fastening clip and
disconnect the equalizer section. Refer to Parking
Brakes in Brake section.
7. Remove the bearing holder fixing nuts.
8. Remove axle shaft assembly, be sure not to damage
the oil seal by axle shaft.
9. Remove differential carrier mounting bolts and nuts.
10. Remove differential assembly.

4B2–3 DRIVE LINE CONTROL SYSTEM (TOD)
detects the slip condition, determines the optimum torque
based on the feedback control logic, and increases the
torque to the front wheels.
The control unit uses the signal from the throttle position
sensor to predict the future vehicle condition and the
intention of the driver with respect to acceleration and
deceleration, and determines the initial torque distribution
using these data and the information from the speed
sensors.
In case of small circle turning in the parking lot, for
example, the control unit minimizes the clutch pressing
force restrict a braking phenomenon. When the ABS
becomes active, the control unit optimizes the clutch
pressing force to ensure stable braking.
TOD Indicator Control
The TOD indicator on the instrument panel informs the
driver of the current working status of the transfer unit.
The information consists of two items: the drive mode
(2H, TOD, 4L, transition) and the torque split status of the
TOD (torque distribution level). The indicator can display
occasional errors and corresponding error codes.

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.
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4H and 4L Switches
Detects the shift position of the transfer from the
movement of the transfer lever and outputs signals to the
TOD control unit.
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Transfer Connector
Transmits the input and output signals of the speed
sensors, electromagnetic coil, and 4H and 4L switches to
the vehicle harness. A waterproof 12-pin type is used.
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TOD Indicator Lamps (on the instrument
panel)
Inform the following items.
Bulb check
Drive mode
ABS IN status
BRAKE ON status
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DRIVE LINE CONTROL SYSTEM (TOD) 4B2–10
Simplified checking method of ABS IN and BRAKE ON signals:
In the event that any of the signal inputs listed below are
observed while the self-diagnostic code is being
displayed (the self-diagnostic connector is short-circuited
to GND), you can simply check the ABS IN and BRAKE
ON signals as shown in the figures below.
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Check Lamp
Check Lamp Valve Check
When the starter switch is turned on in the normal state,
the control unit turns on the CHECK lamp to check the
bulb.
C07RW019

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–14
How to Clear The Trouble Code
The trouble codes saved to the control unit can be deleted
by the following procedure if the starter switch is being in
the OFF position.
1. Shift the transfer lever to the neutral position between
HIGH and 4L, and short-circuit the self-diagnostic
connector.
NOTE: The neutral position between HIGH and 4L refers
to the point that turns off the TOD indicator lamps.
(However, be sure to check the position before
short-circuiting the self-diagnostic connector.)
C07RW011
2. Turn on the starter switch while maintaining the state
of step 1, and step on the brake pedal five times within
five seconds from the first step on. (Note that “five
times” includes the first step on). (The TOD indicator
lamps display the 4L mode whenever the brake pedal
is stepped on.)
3. If the conditions shown in steps 1 and 2 are met, clear
the trouble codes saved to the control unit. (After the
codes are completely deleted, the code 12 that
indicates the normal condition is continuously
displayed.)
Precautions on Diagnosis
Replacement of Control Unit
The control unit itself rarely fails. In most cases, the
harnesses have failed (e.q. short-circuit) to cause
secondary troubles. Other cases include that the cause
has been unknown due to intermittent occurrence of
troubles and the troubles are removed accidentally along
with replacement of control unit, resulting in misjudgment
of cause. Therefore, before replacing the control unit,
check the connector joints and whether the unspecified
current flows in the control unit due to short-circuit
between harnesses.Trouble Intermittently Observed
Troubles intermittently observed are mostly attributable
to temporary imperfect connection of harnesses and
connectors.
When such troubles are found, check the associated
circuit according to the following procedure.
1. Check whether improper connectors are plugged in
or connector terminals are completely engaged.
2. Check whether the terminals are deformed or
damaged. If yes, remove the deformation or damage
and connect the terminals securely.
3. It is likely that wires in the harness are falsely broken.
Therefore, in examination of failed harness circuit,
shake the harness for check to such extent that the
harness will not be damaged.
Test Run of Filed TOD Vehicle
If the TOD indicator lamps experienced faulty operation
even once in the past, the failed portion can be identified
by use of the procedure “Diagnosis from Trouble Codes”
or “Trouble Diagnosis Depending on The Status of TOD
Indicator”. If the troubles that are only recognized as
abnormal phenomena of the vehicle by the driver are
observed, conduct the test run in the following procedure
to reproduce the faulty phenomena and diagnose the fault
for each phenomenon.
1. Start the engine, and check that the TOD indicator
lamps are turned on for about two seconds for initial
check; the CHECK lamp goes off; and the TOD
indicator lamps display the specified drive mode. (If
the CHECK lamp starts blinking, read the trouble
codes and identify the failed portion.)
2. While keeping the vehicle standstill, operate the 4WD
switch and shift the transfer lever to change the
modes: 2H mode
TOD mode4L modeTOD
mode
2H mode. Check that the TOD indicator
lamps correctly display the status whenever the
mode is changed. If the transition status is displayed
during the shift operation, run the vehicle a little to
complete shifting.
3. Slowly start the vehicle in the TOD mode, and add the
power to accelerate to at least 40 km/h and maintain
the speed for about two minutes. Apply the brake to
completely stop the vehicle. Repeat this test pattern
at least three times.
4. Turn the steering to the right end (or left end) in the
TOD mode, and slowly start the vehicle and make a
c i r c l e f i v e t i m e s . N e x t , c o n d u c t t h e s a m e t e s t i n t h e 2 H
mode.
5. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h. Keep the established
speed, carefully change the mode in the sequence
“TOD mode
2H mode TOD mode” while checking
that the shift is complete in each mode change. After
the test, apply the brake to completely stop the
vehicle.
6. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h. Apply the brake
strongly so that the ABS works, and completely stop
the vehicle.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–24
No.NAMECONTENTS
1VIGPower supply (IG)
2N.CNot used
34WD OUT4WD signal output
4SOL (+)Electromagnetic solenoid
5ADC (+)Axle disconnect output
6LIGHTING SWLighting SW input
7BRAKEBrake SW input
84H SW4H SW input
94L SW4L SW input
10AXEL SWAXEL SW input
11ABS INOperation signal input
12TOD SWTOD SW input
13DIAGSelf-diagnosis input
14D-G MAPD-G MAP recognition input (Only V6 engine)
15Ref.Vehicle speed sensor supply
16N.CNot used
17US/JAPDestination recognition input
18COM (–)Vehicle speed sensor GND
19S-GNDSensor GND
20P-GNDPower GND
21TPSThrottle position sensor
22TECH 2TECH 2 output
23Rer. SigRear vehicle speed sensor input
24Frt. SigFront vehicle speed sensor input
25IND.a4WD disply signal a
26IND.b4WD display signal b
27IND.c4WD display signal c
28IND.AUTOAUTO display output
29IND RrRear display output
30CHECKTOD warning lamp

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–26
Checking Failed TOD Control Unit Pin
NOTE:
1. Unplug the ECU connector and the pins, unless
otherwise specified.2. Before removing the ECU, turn off the ignition switch.
3. If the standard values are not observed, check the
pins with other testers.
Check
Pin
No.Circuit to be
testedIgnition
Switch
PositionEngine
StateMultimeter
Scale/
RangeMeasure
between Pin
NumberStandard ValveNote
14D-G MAPOFFSTOP14, 19Continuity : OK
(Gasoline)
20P-GNDOFFSTOP20, 19Continuity : OK
19GNDOFFSTOP19, GNDContinuity : OK
84H SWOFFSTOP8, 19No continuity (high,
4L) and continuity
(N) : OK
94L SWOFFSTOP9, 19No continuity (high)
and continuity (4L,
N) : OK
10AXLE SWONRUN10, 19Continuity : OKRemove ECU and start the engine. Move
the vehicle forth and back to connect axle
surely.
13DIAGOFFSTOP13 (TOD), 8
(DLC Con-
nector)Continuity : OKDLC connector terminal 8
25IND.aONSTOPDCV25 (+), 19 (–)8.0 14.5 VLighting SW ON : 0V
Lighting SW OFF : 8.0 14.5 V
26IND.bONSTOPDCV26 (+), 19 (–)8.0 14.5 V
27IND.cONSTOPDCV27 (+), 19 (–)8.0 14.5 V
30CHECK
LAMPONSTOPDCV30 (+), 19 (–)8.0 14.5 V
11ABS INONSTOPDCV11 (+), 19 (–)11 . 5 14.5 V
15Ref.ONSTOPDCV15 (+), 19 (–)5 9 VConnect ECU
24Ft.(+)ONSTOPDCV24 (+), 19 (–)0.7 6 VConnect ECU (off one tooth of speed
sensor ring) and move the vehicle making
sure of voltage change.
23Rr.(+)ONSTOPDCV23 (+), 19 (–)0.7 6 VConnect ECU (off one tooth of speed
sensor ring) and move the vehicle making
sure of voltage change.
18COM(-)ONSTOPDCV18 (+), 19 (–)0VConnect ECU
1VigONSTOPDCV1 (+), 19 (–)8 14.5 V
7BRAKEOFFSTOPDCV7 (+), 19 (–)8 14.5 VPress brake pedal
21TPSONSTOPDCV21 (+), 19 (–)0.2 4.6 VStep on the accelerator pedal and make
sure that voltage changes.
34WD OUTOFFSTOP3, 197 12 kDisconnect battery GND terminal
5ADC(+)OFFSTOP5, 1910 30 Disconnect battery GND terminal
4SOL(+)OFFSTOP4, 191.0 5.0 Disconnect battery GND terminal
12TOD SWONSTOPDCV12 (+), 19 (–)SW OFF : 0 V
SW ON : 8.0 14.5 VSW OFF : Contact point open
SW ON : Contact point close
6LIGHTINGONSTOPDCV6 (+), 19 (–)SW OFF : 8.0 14.5
V
SW ON : 0 V
28AUTO INDIONSTOPDCV28 (+), 19 (–)TOD : 0 V
2H & 4L : 8.0 14.5
VLighting SW ON : 0V
Lighting SW OFF : 8.0 14.5 V
29RR INDIONSTOPDCV29 (+), 19 (–)0 V
17US/JAPOFFSTOP17 (+), 19 (–)No continuity : OK

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–86
Diagnosis from Symptom
Troubles that are not indicated by the warning lamp are
listed in the table below. These troubles are caused by
the faults that cannot be detected by the self-diagnostic
function of the control unit.
If this type of trouble is observed, interview the customer
and conduct test runs to reproduce the trouble,cross-check the reported trouble with the listed
phenomena, and diagnose and analyze the trouble on the
item by item basis.
PhenomenaMajor causeCorrective action
1The tight corner braking is ob-
served when the vehicle is subject
to full steering.The standard tires are not used.
The tire pressure is incorrect.
The tires are worn inuniformity.
The transfer or wiring is
imperfect.
The limited slip differential is
failed.
Check and recondition the ve-
hicle according to Chart 1.
2Even if the 4WD SW is select to the
4WD position, the 4WD mode is not
active, resulting in remarkable rear
wheel spin.The transfer or wiring is
imperfect.
The shift on the fly system is
failed.
Check and recondition the ve-
hicle according to Chart 2.
3When the 4WD SW is select to
the 4WD position, the drive
resistance of the 4WD system is
too large to get sufficient running
speed.
Noised drive line.
The standard tires are not used.
The tire pressure is incorrect.
The tires are worn inuniformity.
The transfer or wiring is
imperfect.
The limited slip differential is
Check and recondition the ve-
hicle according to Chart 1.
4The shift on the fly system (front
axle) generates gear noises.The wiring is imperfect.
The full automatic free wheel
hub is failed.
Check and recondition the ve-
hicle according to Chart 3.
5The braking distance gets long
even when the ABS is active.The wiring is imperfect.
The ABS is failed.
Check and recondition the ve-
hicle according to Chart 4.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–88
StepActionYe sNo
1Are the front and rear tires in specified size?
Go to Step 2
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
2Is the tire pressure correct?
Go to Step 3
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
3Are the tires free from abnormal wear?
Go to Step 4
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
4Are different types of tires used?
Go to Step 5
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
51. Start the engine.
2. Shift the transfer lever to the high (TOD) position.
3. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 6 Go to Step 11
61. Shift the transfer lever to the 2H position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 7 Go to Step 14
7Is an LSD mounted to the rear differential? Go to Step 8 Go to Step 9
8Is the genuine LSD oil used in the rear differential?
Go to Step 9
Replace the
differential oil.
Go to Step 16
9Does the engine output the power correctly?
Go to Step 10
Check the
engine.
Go to Step 16
10Do the speed sensors work correctly? (Check trouble codes.)The ECU has
failed. Replace
the ECU.
Go to Step 16
Replace the
speed sensors.
Go to Step 16
11Is the tight corner braking observed only when the brake is
applied?
Go to Step 12
Conduct full
steering under
WOT.
Go to Step 5
121. Turn off the starter switch.
2. Disconnect the ECU connector.
Is the battery voltage observed between terminals (B–68)6 and
(B–67)11?
Go to Step 13
Repair the circuit
of terminal 6
(ABS IN).
Go to Step 16

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 distance gets long even when the
ABS is active in the 2H mode.
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