OPEL FRONTERA 1998 Workshop Manual

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.

DIFFERENTIAL (REAR 220mm)
4A2A–5
8. Disconnect the ABS connectors (1) and remove the
brackets (2) attached to the frame and center link
(ABS model only).
350RS001
9. Loosen the brake tube flare nut, remove the clip and
take out the brake tube.
10. Remove the shock absorber fixing nut from the axle
housing.
11. Remove the stabilizer linkage mounting nut from the
axle housing.
12. Remove the lateral rod fixing nut from the axle
housing.
13. Remove the center link mounting bolt and nut from
the axle housing.
14. Remove the trailing link fixing bolt and nut from the
axle housing.
15. Jack down and remove the coil spring and insulator.
16. Axle housing assembly can be separated from the
vehicle on completion of steps 1 – 11.
17. Remove the brake caliper fixing bolt (3), loosen the
flare nut (1), release the clip (2) and take out the brake
caliper together with the flexible hose.
306RS001
18. Remove brake disc.
19. Remove antilock brake system speed sensor fixing
bolt and the clip and bracket on the axle housing
(ABS model only).
20. Remove the brake pipe clip and fixing bolt on the axle
housing and take out the brake pipe.
21. Remove the bearing holder fixing nut and take out the
axle shaft assembly, be sure not to damage the oil
seal by the spline of the shaft, Refer to Axle Shaft in
this section.
22. Remove differential assembly, refer to Differential
Assembly in this section.
Oil Seal Replacement
Remove the oil seal, carefully not to damage the housing,
and mount new oil seal using oil seal installer
5–8840–2294–0.
420RW028
Installation
1. Install differential assembly, refer to Differential
Assembly in this section.
2. Install axle shaft assembly then tighten the bearing
holder mounting nut to the specified torque. Be sure
not to damage the oil seal by the spline of the shaft.
Torque: 74Nꞏm (7.5kgꞏm/54lb ft)
3. Install brake pipe.
4. Connect antilock brake system (ABS) speed sensor
and harness, refer to 4–Wheel Anti–Lock Brake
System (ABS) in Brake section (ABS model only).
5. Install brake disc.
6. Install brake caliper. Refer to Disk Brakes in Brake
section.
7. Install axle housing assembly.
8. Install coil spring and insulator.
9. Install the trailing link fixing bolt and nut to the axle
housing. For the procedures in items 9–13, refer to
Suspension section.
10. Install the center link bolt and nut to the axle housing.

4A2A–6
DIFFERENTIAL (REAR 220mm)
11. Install the lateral rod fixing nut to the axle housing.
12. Install the stabilizer linkage mounting nut to the axle
housing.
13. Install the shock absorber fixing nut to the axle
housing.
14. Install brake tube flare nut, Refer to Disk Brakes in
Brake section.15. Install ABS connector and bracket (ABS model only).
16. Connect breather hose.
17. Install parking brake cable, Refer to Parking Brakes in
Brake section.
18. Bleed brakes. Refer to Hydraulic Brakes in Brake
section.
Pinion Oil Seal
Pinion Oil Seal and Associated Parts
425RW054
Legend
(1) Flange Nut and Washer
(2) Flange(3) Oil Seal
(4) Outer Bearing
(5) Collapsible Spacer
Removal
1.Remove the rear propeller shaft. Refer to Rear
Propeller Shaft in this section.
2. Drain the rear axle oil.

DIFFERENTIAL (REAR 220mm)
4A2A–7
3. Remove flange nut and washer by using pinion flange
holder 5–8840–2157–0 after raising up its staked
parts completely.
415RW028
4. Remove flange.
5. Remove oil seal.
6. Remove outer bearing by using remover
5–8840–2323–0.
425RW066
7. 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. By using the seal installer 5–8840–2165–0, install a
new oil seal (1) that has grease on seal lip.
425RW050
4. Install flange.
5. Install flange nut and washer. Refer to Differential
Assembly in this section for flange nut reassembly.
NOTE: Discard the used nut and install a new one.

4A2A–8
DIFFERENTIAL (REAR 220mm)
Differential Assembly
Differential Assembly and Associated Parts
425RW055
Legend
(1) Bolt and Nut
(2) Axle Shaft Assembly(3) Parking Brake Cable
(4) Differential Assembly
(5) Nut
Removal
1. Jack up and support the frame with stands.
2. Remove the wheel and tire. Refer to Wheel in
Steering section.
3. Drain the differential oil.
4. Remove the propeller shaft. Refer to Rear Propeller
Shaft in this section.
5. Remove the ABS speed sensor(ABS model only).
Refer to 4–Wheel Anti–lock Brake System (ABS) in
Brake section.6. Remove the parking brake cable fastening clip and
disconnect the equalizer section. Refer to Parking
Brakes in Brake section.
7. Remove the bearing holder fixing nuts.
8. Remove axle shaft assembly, be sure not to damage
the oil seal by axle shaft.
9. Remove differential carrier mounting bolts and nuts.
10. Remove differential assembly.

DIFFERENTIAL (REAR 220mm)
4A2A–9
Installation
1. Clean the contact surfaces of the axle and differential
carrier. As shown in the drawing, apply Three Bond
TB1215 or equivalent then install differential
assembly.
425RS006
2. Install bolt and nut. Tighten the differential carrier
mounting bolts and nuts to the specified torque.
Torque:Nuts 44Nꞏm (4.5kgꞏm/33lb ft)
Bolts 66Nꞏm (6.7kgꞏm/48lb ft)
3. Install axle shaft assembly. Be sure not to damage
the oil seal by axle shaft.
4. Install nut, refer to Axle Shaft in this section.
5. Install parking brake cable, refer to Parking Brakes in
Brake section.
NOTE: After completing the assembling work, fill the
prescribed gear oil to the filler hole.
Lubricant capacity: 1.8 liter (1.6 Imp qt/1.9US
qt)
6. Tighten the oil filler plug to the specified torque.
Torque: 78Nꞏm (8.0kgꞏm/58lb ft)

4A2A–10
DIFFERENTIAL (REAR 220mm)
Disassembled View
415RW035
Legend
(1) Bolt
(2) Bearing Cap
(3) Side Bearing
(4) Adjust Shim
(5) Diff Cage Assembly
(6) Side Bearing Outer Race
(7) Pinion Gear
(8) Adjust Shim
(9) Inner Bearing (10) Inner Bearing Outer Race
(11) Collapsible Spacer
(12) Differential Carrier
(13) Outer Bearing Outer Race
(14) Outer Bearing
(15) Oil Seal
(16) Dust Cover
(17) Flange
(18) Flange Nut

DIFFERENTIAL (REAR 220mm)
4A2A–11
Disassembly
1. Using holding fixture 5–8840–0275–0 and holding
fixture base 5–8840–0003–0, fix the differential
assembly to the bench.
425RW046
2. Remove bearing cap bolt.
3. Apply a setting mark to the side bearing cap and the
differential carrier then remove bearing cap.
425RS009
4. Remove differential cage assembly.
5. Remove side bearing outer race, after removal, keep
the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.6. Remove side bearing, using remover
5–8840–0013/0014–0 and adapter 5–8840–2196–0.
415RW031
7. Remove adjust shim, note the thickness and position
of the shims removed.
8. Remove the flange nut using holding wrench
5–8840–2157–0 after raising up its staked parts
completely.
425RW057
9. Remove flange.
10. Remove dust cover.

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