Differential oil OPEL FRONTERA 1998 Owner's Manual

4A2A–12
DIFFERENTIAL (REAR 220mm)
11. Remove the drive pinion assembly using a soft metal
rod and a hammer.
425RW056
12. Remove collapsible spacer.
13. Remove the inner bearing using a separator
5–8840–2197–0 and a press.
415RW039
14. Remove adjust shim.
15. Remove inner bearing outer race.
16. Remove oil seal.
17. Remove outer bearing.18. Remove the inner bearing outer race (1) and the outer
bearing outer race (2) by using a brass bar and a
hammer.
425RS014
425RS015

DIFFERENTIAL (REAR 220mm)
4A2A–13
Reassembly
1. Using installer 5–8840–2164–0 and grip
5–8840–0007–0, install outer bearing outer race.
415RW025
2. Using installer 5–8840–2163–0 and grip
5–8840–0007–0, install Inner bearing outer race.
415RW026
3. Install adjust shim and adjust drive pinion mounting
distance
1. Apply gear oil to the inner and outer drive pinion
bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the inner
and outer bearings.2. Tighten the nut to the specified torque.
Torque: 2.3 Nꞏm (0.23kgꞏm/20 lb in)
415RW037
Legend
(1) Front Pilot: 5–8840–2085–0
(2) Rear Pilot: 5–8840–0129–0
(3) Gauge Plate: 5–8840–2166–0
(4) Bolt and Nut: 5–8840–0127–0
3. Clean the side bearing bores. Install the dial
indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft)
415RW038
Legend
(1) Dial Indicator: 5–8840–0126–0
(2) Disc (2 pcs.): 5–8840–2167–0
(3) Arbor: 5–8840–0128–0
(4) Gauge Plate: 5–8840–2166–0

4A2A–16
DIFFERENTIAL (REAR 220mm)
4. Place the shim on the drive pinion, with the chamfered
side turned towards the pinion head then install the
inner bearing onto the pinion using an installer
9–8522–1165–0 and a press.
NOTE: Do not apply pressure to the roller cage and apply
pressure only to the inner race.
425RW048
5. Discard the used collapsible spacer and install a new
one.
6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer 5–8840–2165–0 to install a new
oil seal that has been soaked in rear axle lubricant.
NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.
415RW029
9. Install dust cover.
10. Install flange.
11. Install flange nut.
1. Apply lubricant to the pinion threads.2. Tighten the nut to the specified torque using the
pinion flange holder 5–8840–2157–0.
Torque: 245–294Nꞏm (25.0–28.0kgꞏm/181–217 lb f
t)
NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
425RW057
3. Adjust pinion bearing preload.
a. Measure the bearing preload by using a torque
meter. Note the scale reading required to
rotate the flange.
b. Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bear-
ing 0.7–1.3 Nꞏm(0.07-0.13kgꞏm/6.08–11.28 lb in)
Used bear-
ing 0.4–0.6Nꞏm(0.04–0.06kgꞏm/3.04-5.64 Ib in)
425RS027
4. Using punch 5–8840–2293–0, stake the flange
nut at two points.

4A2A–22
DIFFERENTIAL (REAR 220mm)
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

DIFFERENTIAL (REAR 220mm)
4A2A–27
Pressure ring
425RS057
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

4A2A–28
DIFFERENTIAL (REAR 220mm)
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.
Measure the Deformation of the friction disc & plate.
Limit: 0.08 mm (0.003 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): 80.58 mm (3.17 in)
(C): 10.58 mm (0.41 in)
425RS064
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.

4A2A–30
DIFFERENTIAL (REAR 220mm)
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.
425RS068
Legend
(1) Friction Plate
(2) Spring Disc
(3) Friction Disc
4. Inatall Spring disc.
5. Inatall Friction plate.
6. Inatall Friction disc.
7. Inatall Friction plate.
8. Inatall Friction disc.
9. Inatall Pressure ring.
10. Inatall Side gear.
11. Inatall Pinion and pinion shaft.
12. Inatall Side gear.
13. Inatall Pressure ring.
14. Inatall Friction disc.15. Inatall Friction plate.
16. Inatall Friction disc.
17. Inatall Friction plate.
18. Inatall Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct.
19. Inatall Spring disc.
20. Inatall Thrust washer.
21. Inatall Differential cage A.
22. Inatall 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)
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

DIFFERENTIAL (REAR 220mm)
4A2A–35
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
5–8840–2381–0
(J–41033)
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–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2B–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2B–4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2B–4. . . . . .
Removal 4A2B–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2B–5. . . . . . . . . . . . . . . . . .
Installation 4A2B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2B–6. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2B–6. . . . .
Removal 4A2B–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–7. . . . . . . . . . . . . . . . . .
Installation 4A2B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A2B–8. . . . . . . . . . . . . . . . . . . .
Differential Assembly and Associated Parts 4A2B–8
Removal 4A2B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A2B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2B–10. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–11. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A2B–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A2B–20. . . . . . . . . . . . . . .
Disassembled View 4A2B–20. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–21. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Locking Differential Assembly 4A2B–23. . . . . . . . . . . . .
Disassembled View 4A2B–23. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–25. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–25. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A2B–27. . . . . . . . . . . . .
Special Tools 4A2B–29. . . . . . . . . . . . . . . . . . . . . . . . . . .
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
c l a m p i n g f o r c e , a n d m a y d a m a g e t h e f a s t e n e r. W h e n
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.