oil OPEL FRONTERA 1998 Owner's Manual

DIFFERENTIAL (FRONT) 4A1–6
3. Remove the drain bolt to drain differential oil.
NOTE:
a. During the work, be sure that the diff case is
supported by the jack.
412RS003
b. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Front Disc Brake Caliper Assembly
in Brake section.
c. Remove the antilock brake system speed sensor (if
equipped). Refer to Front Wheel Speed Sensor in
Brakes section.
4. Remove the hub assembly (Disc, back plate and
knuckle), refer to Front Hub and Disc in this section.
5. Disconnect the knuckle and the suspension arm.
Refer to Suspension section.
6. Remove steering link and arm assembly, refer to
Steering Linkage in Steering section.
7. Remove suspension crossmember.
8. Remove propeller shaft, refer to Front Propeller Shaft
in this section.
9. Remove protector (Shift on the fly model).
10. Remove breather hose (Shift on the fly model).
11. Remove the hose clip (Shift on the fly model).
12. Disconnect breather hose from front drive axle tube
and disconnect housing (Shift on the fly model).
13. Disconnect vacuum hose from actuator (Shift on the
fly model).14. Disconnect shift switch connector (Shift on the fly
model).
412RS031
15. Remove VSV assembly (1) (Shift on the fly model).
NOTE: Be sure not to remove hose and connector from
VSV asm.
412RW002

4A1–9 DIFFERENTIAL (FRONT)
Differential Assembly
Disassembled View
415RW001
Legend
(1) Differential Assembly
(2) Flange Nut
(3) Flange
(4) Dust Cover
(5) Oil Seal
(6) Outer Bearing
(7) Outer Bearing Outer Race
(8) Damper
(9) Bracket
(10) Differential Carrier
(11) Bearing Cap(12) Bolt
(13) Inner Bearing Outer Race
(14) Collapsible Spacer
(15) Pinion Gear
(16) Inner Bearing
(17) Adjust Shim
(18) Diff Cage Assembly
(19) Side Bearing Outer Race
(20) Side Bearing
(21) Adjust Shim
(22) Bolt
(23) Axle Case
Disassembly
1. Remove differential carrier fixing bolt.2. Remove differential assembly.

4A1–11 DIFFERENTIAL (FRONT)
13. Remove the drive pinion assembly using a soft metal
rod and a hammer.
425RW041
14. Remove collapsible spacer.
15. Remove the inner bearing using a separator
5–8840–0015–0 and a press.
415RW033
16. Remove adjust shim.
17. Remove inner bearing outer race.
18. Remove oil seal.
19. Remove outer bearing.20. 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 (FRONT) 4A1–12
21. Remove damper and bracket.
425RW042
Reassembly
1. Using installer 9–8522–1141–0 and grip
5–8840–0007–0, install outer bearing outer race.
415RW018
2. Using installer 9–8522–1274–0 and grip
5–8840–0007–0, install Inner bearing outer race.
415RW017
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)
415RS009
Legend
(1) Pilot : 5–8840–2085–0
(2) Nut and Bolt : 5–8840–2089–0
(3) Gauge Plate : 5–8840–2087–0

DIFFERENTIAL (FRONT) 4A1–16
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 9–8522–1275–0 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.
415RW024
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: 177–275Nꞏm (18–28kgꞏm/130–203 lb ft)
NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
425RW047
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 0.7–1.1 Nꞏm(0.065–0.115kgꞏm/5.64–9.98 lb in)
Used bear-
ing 0.4–0.5Nꞏm(0.033–0.057kgꞏm/2.86–4.94 Ib in)
425RS027
4. Using punch 5-8840-2293-0, stake the flange nut
at two points.

DIFFERENTIAL (FRONT) 4A1–22
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 (11kgꞏm/80 lb ft)5. Tighten the fixing bolts in a diagonal sequence as
illustrated.
415RS016
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

4A1–25 DIFFERENTIAL (FRONT)
Main Data and Specifications
General Specifications
Axle tube TypeIt consists of the duct, a cast iron housing and the axle
tube.
Gear typeHypoid
Gear ratio(to 1)4.100(6VE1)
4.300(4JX1, 6VE1)
4.555(4JG2–TC, 6VD1)
4.777(4JG2)
Differential typeTwo pinion
Oil capacityliter
(Imp qt/US qt)1.4 (1.2/1.5) (Differential)
0.12 (0.11/0.13) (Actuator Housing: Shift on the fly)
Type of lubricant75W–90 GL–5 (Multi grade type)
Refer to General Information
Axle shaft typeConstant velocity joint
(Birfield joint type and double offset joint)

DIFFERENTIAL (FRONT) 4A1–28
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2157–0
(J–37221)
Holder; Pinion flange
9–8522–1275–0
(J–24250)
Installer; Oil seal
5–8840–0275–0
(J–37264)
Differential holding
fixture
(Use with
5–8840–0003–0 base)
5–8840–0003–0
(J–3289–20)
Holding fixture base
5–8840–0013–0
5–8840–0014–0
(J–22888)
Puller; Side bearing
9–8521–1743–0
(J–8107–2)
Adapter; Side bearing
plug
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–0015–0
(J–22912–01)
Separator
9–8522–1141–0
(J–24256)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Driver handle
9–8522–1274–0
(J–24252)
Installer; Inner bearing
outer race
5–8840–2085–0
(J–21777–42)
Pilot
5–8840–2089–0
(J–23597–9)
Nut and bolt

DIFFERENTIAL (REAR 220mm)
4A2A–1
DRIVELINE/AXLE
DIFFERENTIAL (Rear 220mm)
CONTENTS
Service Precaution 4A2A–1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2A–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2A–4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2A–4. . . . . .
Removal 4A2A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2A–5. . . . . . . . . . . . . . . . . .
Installation 4A2A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2A–6. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2A–6. . . . .
Removal 4A2A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2A–7. . . . . . . . . . . . . . . . . .
Installation 4A2A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A2A–8. . . . . . . . . . . . . . . . . . . .
Differential Assembly and Associated Parts 4A2A–8
Removal 4A2A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A2A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2A–10. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2A–11. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A2A–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A2A–21. . . . . . . . . . . . . . .
Disassembled View 4A2A–21. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2A–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2A–22. . . . . . . . . . . . . . . . . .
Reassembly 4A2A–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Slip Differential 4A2A–25. . . . . . . . . . . . . . . . . . .
Disassembled View 4A2A–25. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2A–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2A–26. . . . . . . . . . . . . . . . . .
Reassembly 4A2A–28. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A2A–32. . . . . . . . . . .
Special Tools 4A2A–34. . . . . . . . . . . . . . . . . . . . . . . . . .
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.

4A2A–4
DIFFERENTIAL (REAR 220mm)
Axle Housing
Axle Housing and Associated Parts
420RW022
Legend
(1) Coil Spring and Insulator
(2) Axle Housing Assembly
(3) ABS Speed Sensor and Harness(if equipped)
(4) Nut
(5) Parking Brake Cable
(6) Bolt and Nut
(7) Antilock Brake System (ABS) Connector and
Bracket (if equipped)
(8) Bolt and Nut(9) Nut
(10) Differential Assembly
(11) Axle Shaft Assembly
(12) Brake Disc
(13) Brake Pipe
(14) Brake Caliper
(15) Nut
(16) Breather Hose
(17) Flare Nut
Removal
1. Raise the vehicle and support it with suitable safety
stands.
The hoist must remain under the rear axle housing.
2. Drain brake fluid. Refer to Hydraulic Brakes in Brake
section.
3. Remove rear wheels and tires. Refer to Wheel in
Suspension section.4. Remove propeller shaft. Refer to Rear Propeller
Shaft in this section.
5. Drain the rear axle oil into a proper container.
6. Remove parking brake cable, release the connection
between the cable fixing clip equalizer. Refer to
Parking Brakes in Brake section.
7. Move the clip aside and pull out the breather hose.