oil OPEL FRONTERA 1998 Repair Manual

4A2B–8DIFFERENTIAL (REAR 244mm)
Differential Assembly
Differential Assembly and Associated Parts
425RW044
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. Refer to Anti–lock
Brake System in Brakes 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 244mm)
4A2B–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/33 lb ft)
Bolts 64Nꞏm (6.5kgꞏm/47 lb 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: 3.0 liter (2.6 Imp qt/3.2
US qt)
6. Tighten the oil filler plug to the specified torque.
Torque: 78Nꞏm (8.0kgꞏm/58 lb ft)

4A2B–10DIFFERENTIAL (REAR 244mm)
Disassembled View
415RW002
Legend
(1) Flange Nut and Washer
(2) Flange
(3) Oil Seal
(4) Oil Seal Slinger
(5) Outer Bearing
(6) Outer Bearing Outer Race
(7) Diff Carrier
(8) Bearing Cap
(9) Bolt(10) Inner Bearing Outer Race
(11) Collapsible Spacer
(12) Inner Bearing
(13) Adjust Shim (Pinion Position)
(14) Drive Pinion Shaft
(15) Adjust Shim (Diff Cage Assembly)
(16) Diff Preload/Backlash
(17) Side Bearing
(18) Side Bearing Outer Race

4A2B–12DIFFERENTIAL (REAR 244mm)
8. Removed flange assembly.
9. Remove the drive pinion assembly using a soft metal
rod and a hammer.
425RS012
10. Remove collapsible spacer.
11. Remove the inner bearing by using remover
5–8840–2587–0. Select insert 303174 and collet
halves 44803 in remover kit 5–8840–2587–0 for inner
bearing removal.
415RW042
12. Remove adjust shim.
13. Remove oil seal.
14. Remove oil seal slinger.
15. Remove outer bearing.
16. 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 244mm)
4A2B–13
Reassembly
1. Install outer bearing outer race by using installer
5–8840–0008–0 and grip 5–8840–0007–0.
425RW059
2. Install inner bearing outer race by using installer
5–8840–2571–0 and grip 5–8840–0007–0.
425RW060
3. Adjust the drive pinion mounting distance as follows:
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.
Install gauge plate 5–8840–2572–0 (3), inner pilot
5–8840–2573–0 (2) ,stud and nut 5–8840–0127–0
(4) and outer pilot 5–8840–2575–0 (1) through inner
and outer bearings.2. Tighten the nut to the specified torque.
Torque: 2.3 Nꞏm (23kgꞏcm/20 lb in)
425RW030
3. Clean the side bearing bores. Place discs and dial
indicator on to arbor, and place tool into position in
side bearing bores. Install and tighten the bearing
caps to the specified torque.
425RW031
Legend
(1) Dial Indicator: 5–8840–0126–0
(2) Gauge Plate: 5–8840–2572–0
(3) Disc (2 pcs.): 5–8840–2577–0
(4) Arbor: 5–8840–0128–0

4A2B–16DIFFERENTIAL (REAR 244mm)
4. Place the shim (1) on the drive pinion, then install the
inner bearing (2) onto the pinion by using installer
5–8840–2574–0 and a press .
NOTE: Do not apply pressure to the roller cage. Apply
pressure only to the inner race.
425RW061
5. Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
6. Install drive pinion shaft assembly.
7. Install outer bearing and oil seal slinger.
8. Use oil seal installer 5–8840–2165–0 to install a new
oil seal that has grease on seal lip.
415RW029
9. Install flange assembly.10. Install flange nut and washer.
1. Apply lubricant to the pinion threads.
2. Using the pinion flange holder 5–8840–0133–0,
tighten the nut only enough to remove the shaft
end play.
NOTE: Discard used flange nut and install new one.
415RW006
3. Adjust pinion bearing preload.
a. Measure the bearing preload by using a torque
meter and note the scale reading required to
rotate the flange.
b. Continue tightening flange nut until the specified
starting torque is obtained.
Starting torque: 1.1–1.6 Nꞏm (11–16kgꞏcm/10–14
lb in)
NOTE:
a. Do not overtighten or loosen and then retighten the
nut.
b. Pinion nut torque should be in the range of
298–380 Nꞏm (30.4–38.8kgꞏm/220–281 Ib ft).
425RW018

DIFFERENTIAL (REAR 244mm)
4A2B–21
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin using a small drift.
425RS042
4. Remove the differential shaft by using a hard metal
rod and a hammer.
425RS043
5. Remove pinion mate gear and thrust washer.
6. Remove side gear and 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:
Ring gear, pinion gear
Bearing
Side gear, pinion mate gear, differential shaft
Differential cage, carrier
Thrust washer
Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
3. Tighten the fixing bolts in a diagonal sequence as
illustrated.
Torque: 177Nꞏm (18.0kgꞏm/130 lb ft)
425RW033
Reassembly
425RS048
1. Install side gear with thrust washer.

DIFFERENTIAL (REAR 244mm)
4A2B–29
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
5–8840–0008–0
(J–8611–01)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Grip
5–8840–2571–0
(J–42831)
Installer; Inner bearing
outer race
5–8840–2575–0
(J–42824)
Pilot;Outer
5–8840–0127–0
(J–21777–43)
Nut & Stud

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–2
General Description
C07RW014–1
TOD (Torque on Demand) system is traction state control
system to vehicle.
Transfer Position and Drive Mode
Three drive modes can be selected through operation of
4WD switch and transfer lever.
Transfer Position
TOD SWModeDrive mode
HIGHON (NORMAL)2HRear wheel drive
OFF (PUSHED)TODElectronically controlled torque split
four wheel drive
4LON/OFF4LLow-speed mechanical lock-up four
wheel drive
The electronic control unit (ECU) judges the signals from
the transfer lever and controls the transfer drive mode
and shift-on-the-fly system status.
TOD Control
The TOD position usually drives the rear wheels, and
transmits the torque to the front wheels with the help of
electronically controlled torque split mechanism
according to running conditions encountered. The driving
force is directly transmitted to the rear wheels. This force
is split by the transfer and delivered to the front wheels.
The magnitude of the torque transmitted to the front
wheels is controlled by changing the pressing force of the
electromagnetic multi plate disk clutch built in the transfer
unit. The pressing force of the clutch is controlled bychanging the voltage to the electromagnetic coil mounted
to the rear of the clutch. When the clutch is completely
disengaged, the rear wheels are driven. When the clutch
is completely engaged, a rigid four wheel drive mode is
obtained. The torque split status is controlled
continuously between the rear wheel and four wheel drive
modes. This system includes front and rear speed
sensors, and throttle position sensor that monitors the
engine output.
The control unit receives signals sent from these sensors
and changes the pressing force of the electromagnetic
multi plate disk clutch to determine the torque distribution
on the front and rear wheels. Therefore, when the slip of
the rear wheels is increased against the current torque
level in the normal rear wheel drive mode, the control unit

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–4
System Components
Parts Location
A07RW020
Legend
(1) T/F Connector
(2) 4H Switch and 4L Switch
(3) High-Low Planetary Gear Set
(4) Mechanical Lock(5) Multi Plate Disk Clutch Pack
(6) Electromagnetic Coil
(7) Rear Speed Sensor
(8) Front Speed Sensor