wheel OPEL FRONTERA 1998 Workshop Manual

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–114
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
observed 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
vehicle according to Chart 1.
2Even if the 4WD AUTO 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
vehicle according to Chart 2.
3When the 4WD AUTO SW is
selected 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
failed.
Check and recondition the
vehicle according to Chart 1.
4The shift on the fly system (front
axle) generates gear noises.The wiring is imperfect.
The shift on the fly system is
failed.
Check and recondition the
vehicle 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
vehicle according to Chart 4.

4B2–117 DRIVE LINE CONTROL SYSTEM (TOD)
StepNo Ye s Action
131. Apply the brake and fully turn the steering to the left (or right)
end, and start the creep run.
Does the voltage between terminals 4 and 20 range between 0.1
and 1.0V?Repair the
transfer
assembly.
Go to Step 16The ECU has
failed. Replace
the ECU.
Go to Step 16
141. Shift the transfer lever to the high position and switch the 4WD
AUTO SW to 4WD position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the voltage between terminals 4 and 20 range between 0.1
and 1.0V?
Go to Step 15 Go to Step 10
151. Select the 4WD AUTO SW to the 2WD position.
2. Jack up the right front wheel.
Does the front tire rotate smoothly?The phenomenon
is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
Go to Step 16
Repair the
transfer
assembly.
Go to Step 16
16Check that all the parts are mounted.
Is this step complete?Repeat the
“Diagnosis Flow”.
Return to Step 16
*NOTE: Before checking this item, run the vehicle more
than 10 meters with the steering wheel in straight position
so that the 4L mechanical lock sleeve can be released
certainly.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–118
Chart 2The 4WD mode is not active.
Function of circuit—
Fail conditionThe rear wheels spin in the TOD mode, so the driving torque is not transmitted to the
front wheels. The indicator lamps will not show the 4L and TOD status.
D04RY00073

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–120
Chart 3The shift on the fly system generates gear noises.
(The fuel economy is bad in the 2H mode.)
Function of circuit—
Fail conditionWhen the vehicle is run in the 2H mode, the shift on the fly system generates gear
noises or the front wheel gears are engaged to generate a shock.
D04RY00073

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.

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 Assembly
(7) Bearing Holder(8) Bearing
(9) Retainer
(10) Snap Ring
(11) Bolt
(12) Nut
(13) Antilock Brake System (ABS) Speed Sensor (if
so equipped)
Removal
1. Raise the vehicle.
2. Remove tires and wheels. Refer to Wheel in Steering
section.3. Remove brake caliper. Use a wire to attach the brake
caliper to the frame. Refer to Disk Brakes in Brake
section.
4. Remove brake disc.
5. Remove ABS sensor (if so equipped).
6. Remove Parking brake assembly. Refer to Parking
Brakes in Brake section.

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 not to damage the oil seal.
10. Remove snap ring.
11. Using a bearing remover 5–8840–2295–0 and press,
remove retainer together with the bearing holder.
420RW024
12. Remove bearing.
13. Remove bearing holder.
14. Remove back plate.15. Remove the wheel pins using a remover
5–8840–0079–0.
420RW023
Inspection and Repair
Make necessary correction or parts replacement if wear,
corrosion or any other abnormal conditions are found
through inspection.
Visual Check:
Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Axle shaft
2. Bearing
When checking the axle shaft, pay special attention to the
splined portions and replace the shaft if distortion or step
wear is noticeable. Correct slight step wear with a grinder.
420RS008

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 to damage the bearing
holder bore .
When installing, use oil seal installer 5–8840–2310–0.
420RW026
Installation
1. Install wheel pin.
2. Install back plate.
3. Install bearing holder.
4. Install bearing.
5. Install retainer by using a bearing installer
5–8840–2296–0, press fit together with the bearing.
420RW027
6. Install snap ring.
7. Install axle shaft assembly.
NOTE: Be sure not to damage the oil seal.
8. Tighten the bearing holder mounting nut to the
specified torque.
Torque: 74Nꞏm (7.5kgꞏm/54 Ib ft)

4C–8
DRIVE SHAFT SYSTEM
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–0079–0
(J–6627–A)
Wheel pin remover
5–8840–2295–0
(J–39211)
Remover; Axle shaft
bearing
5–8840–2296–0
(J–39212)
Installer; Axle shaft
bearing
5–8840–2310–0
(J–39379)
Installer; Outer axle seal

4C–9 DRIVE SHAFT SYSTEM
Front Hub and Disc (with Shift on the Fly)
Disassembled View
411RW001
Legend
(1) Bolt
(2) Cap
(3) Snap Ring and Shim
(4) Hub Flange
(5) Lock Washer and Lock Screw
(6) Hub Nut(7) Outer Bearing
(8) Bolt
(9) Hub and Disc Assembly
(10) Wheel Pin
(11) ABS Sensor Ring (If equipped)
(12) Inner Bearing
(13) Oil Seal
Disassembly
1. Before disassembly, select the 2WD position.
2. Jack up the front of vehicle and support frame with
jack stands.3. Remove the disc brake caliper assembly and hang it
on the frame with wires. Refer to Front Disc Brake
Caliper Assembly in Brakes section.
4. Remove bolt.
5. Remove cap.
6. Remove snap ring and shim.
7. Remove hub flange.