OPEL FRONTERA 1998 Workshop Manual

DIFFERENTIAL (FRONT) 4A1–4
3. Remove the front propeller shaft. Refer to Front
Propeller Shaft in this section.
4. Remove flange nut by using pinion flange holder
5–8840–2157–0.
425RW045
5. Remove flange.
6. Remove oil seal.
7. Remove outer bearing by using remover
5–8840–2323–0.
415RW022
8. Remove collapsible spacer.
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. Seal surface of the pinion.
2. Cage bore for burns.
Installation
1. Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
2. Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.
3. Install oil seal, use oil seal installer 9–8522–1275–0 to
install a new oil seal that has been soaked in axle
lubricant.
415RW021
4. Install flange.
5. Install flange nut, refer to Differential Assembly for
flange nut reassembly in this section.
NOTE: Discard the used nut and install a new one.

4A1–5 DIFFERENTIAL (FRONT)
Front Drive Axle Assembly
Front Drive Axle Assembly and Associated Parts
412RW001
Legend
(1) Mounting Bolt and Nut
(2) Washer and Spacer
(3) Breather Hose (with Shift on the Fly)
(4) Shift Switch Connector (with Shift on the Fly)
(5) Protector (with Shift on the Fly)(6) Front Axle Case Assembly and Front Drive
Shaft Assembly (LH side)
(7) Hub Assembly (Disc, Back Plate and Knuckle)
(8) Front Drive Shaft Assembly (RH side)
(9) Propeller Shaft (With TOD)
(10) Propeller Shaft
(11) Bolt
Removal
1. Jack up the vehicle and support it using jack stands.
2. Remove the tire and wheel.

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

4A1–7 DIFFERENTIAL (FRONT)
16. Remove mounting bolt and nut.
412RS004
17. Remove washer and spacer.
18. Remove the mounting bracket fixing bolt.
412RS005
19. Lower the vehicle and disconnect the RH front drive
shaft assembly, then remove the front axle case
assembly and front drive shaft assembly (LH).
412RS006
20. Remove front drive shaft assembly (RH).
Installation
1. Install front drive shaft assembly (RH) and lay the
assembly on the lower arm.
2. Install front axle case assembly and front drive shaft
assembly (LH) and place the axle case on the jack,
connect to the front drive shaft assembly (RH) before
installing to the vehicle.
3. Install bolt and tighten the mounting bracket fixing bolt
to the specified torque.
Torque: 116 Nꞏm (11.8kgꞏm/85 lb ft)
4. Install washer and spacer.

DIFFERENTIAL (FRONT) 4A1–8
5. Tighten the mounting bolt and nut to the specified
torque.
Torque: 152 Nꞏm (15.5kgꞏm/112 lb ft)
412RW005
Legend
(1) Frame
(2) Spacer
(3) Washer
(4) Bolt
(5) Nut
6. Install VSV assembly and tighten nuts to specified
torque (Shift on the fly model).
Torque: 8 Nꞏm (0.8kgꞏm/69 lb in)
7. Install the shift switch connector (Shift on the fly
model).
NOTE: Be careful not to permit the entry of dust into the
connector.
8. Install the actuator side of vacuum hose (Shift on the
fly model).
NOTE: Be careful not to permit the entry of dust into the
hose.
9. Connect breather hose and install the hose clip (Shift
on the fly model).
10. Install protector and tighten bolts to specified torque
(Shift on the fly model).
Torque: 26 Nꞏm (2.7kgꞏm/20 lb ft)
11. Install propeller shaft, refer to Front Propeller Shaft in
this section.
12. Install suspension crossmember.
13. Steering link and arm assembly, refer to Steering
Linkage in Steering section.
14. Install hub assembly (Disc, back plate and knuckle),
refer to Front Hub and Disc in this section.

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.

DIFFERENTIAL (FRONT) 4A1–10
3. Using holding fixture 5–8840–0275–0 and holding
fixture base 5–8840–0003–0, fix the differential
assembly to the bench.
425RW046
4. Remove bearing cap bolt.
5. Apply a setting mark to the side bearing cap and the
differential carrier then remove bearing cap.
425RS009
6. Remove differential cage assembly.
7. Remove side bearing outer race, after removal, keep
the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.8. Remove side bearing, using remover
5–8840–0013–0, 5–8840–0014–0 and adapter
9–8521–1743–0.
415RW023
9. Remove adjust shim, note the thickness and position
of the shims removed.
10. Remove the flange nut using holding wrench
5–8840–2157–0 after raising up its staked parts
completely.
425RW047
11. Remove flange.
12. Remove dust cover.

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

4A1–13 DIFFERENTIAL (FRONT)
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.
To r q u e : 9 8 N ꞏm ( 1 0 k g ꞏm / 7 2 l b f t )
415RS010
Legend
(1) Dial Indicator: 5–8840–0126–0
(2) Disc (2 pcs.): 5-8840-2088-0
(3) Arbor: 5–8840–0128–0
(4) Gauge Plate: 5–8840–2087–0
4. Set the dial indicator to “0”. Place it on the
mounting post of the gauging arbor with the
contact button touching the indicator pad. Force
the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the dial
indicator in this position.
425RS020
Legend
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gauge Plate
5. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate
the position at which the dial indicator shows the
greatest defection. At this point, once again set
the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.
425RS021
6. After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does not
touch the gauging plate.
Record the number the dial indicator needle
points to.
425RS022
Legend
(1) Example=Dial indicator reading of 0.085