differential OPEL FRONTERA 1998 Workshop Manual

4A2B–34DIFFERENTIAL (REAR 244mm)
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 244mm)
4A2B–35
Main Data and Specifications
General Specifications
Rear axle
Ty p eBanjo, Semi–floating
Rear axle Size244 mm (9.61 in)
Gear typeHypoid
Gear ratio (to 1)4.100(6VE1 with A/T)
4.300(6VE1 with M/T,4JX1)
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.
Capacity3.0 liter (2.6 Imp qt/3.2 US qt)

4A2B–36DIFFERENTIAL (REAR 244mm)
Torque Specifications
420RY00002

DIFFERENTIAL (REAR 244mm)
4A2B–37
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2294–0
(J–39210)
Installer; Axle shaft inner
seal
5–8840–0133–0
(J–8614–01)
Pinion flange holder
5–8840–2165–0
(J–37263)
Installer; Pinion oil seal
5–8840–2029–0
(J–42832)
Holding fixture
5–8840–0003–0
(J–3289–20)
Holding fixture base
5–8840–2587–0
(J–42379)
Remover; Bearing
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2576–0
(J–8107–3)
Adapter; Side bearing
plug
5–8840–2689–0
(J–44461)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Grip
5–8840–2690–0
(J–44462)
Installer; Inner bearing
outer race
5–8840–2681–0
(J–42824)
Pilot;Outer
5–8840–0127–0
(J–21777–43)
Nut & Bolt

4A2B–38DIFFERENTIAL (REAR 244mm)
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2680–0
(J–44453)
Pilot; Inner
5–8840–2681
(J–44449)
Pilot; Outer bearing
5–8840–2678–0
(J–44451)
Gage plate
5–8840–0126–0
(J–8001)
Dial indicator
5–8840–2679–0
(J–44452)
Disc (2 required)
5–8840–0128–0
(J–23597–1)
Arbor
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2574–0
(J–42828)
Installer; Pinion bearing
5–8840–2293–0
(J–39209)
Punch; End nut lock
5–8840–2570–0
(J–42829)
Installer; Side bearing
5–8840–2323–0
(J–39602)
Remover; Outer bearing
5–8840–2586–0
(J–39858)
Clutch pack unloading
tool kit Includes
Screw cap, Cap and
Forcing screw

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.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–116
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
In flate tries to
recommended
pressure.
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 position and switch the 4WD
AUTO SW to 4WD 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 high position and switch the 4WD
AUTO SW 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 on the starter switch.
Is the battery voltage observed between terminals 11 and 19?
Go to Step 13
Repair the circuit
of terminal 11
(ABS IN).
Go to Step 16

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–23 DRIVE SHAFT SYSTEM
Front Axle Drive Shaft
Front Axle Drive Shaft and Associated Parts
This illustration is based on the model equipped with shift on the fly system.
412RW003
Legend
(1) Axle Case and Differential
(2) DOJ Case Assembly
(3) Snap Ring
(4) Bearing
(5) Snap Ring
(6) Oil Seal
(7) Bracket
(8) DOJ Case
(9) Circlip
(10) Bolt
(11) Drive Shaft Joint Assembly
(12) Snap Ring(13) Spacer
(14) Ball
(15) Snap Ring
(16) Ball Retainer
(17) Ball Guide
(18) Band
(19) Bellows
(20) Band
(21) Band
(22) Bellows
(23) Band
(24) BJ Shaft
(25) Dust Seal

4C–33 DRIVE SHAFT SYSTEM
412RS037
Reassembly
1. Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer
5–8840–2407–0 and grip 5–8840–0007–0.
412RS043
2. Force a new needle bearing into inner shaft by using a
installer 5–8840–2408–0 and grip 5–8840–0007–0.
412RS051
3. Place a new snap ring(internal) in inner shaft.
Force a new inner shaft bearing into the inner shaft by
using a installer 5–8840–2197–0 and press.
412RS044
4. Install snap ring(external).
NOTE: Be careful not to damage the inner shaft.
5. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.