oil OPEL FRONTERA 1998 Workshop Manual

DIFFERENTIAL (REAR 220mm)
4A2A–9
6. Install snap ring.
7. Install axle shaft assembly.
NOTE: Be sure not to damage the oil seal.
8. Tighten the bearing holder mounting nut to the
specified torque.
Torque: 74Nꞏm (54 Ib ft)
9. Fix the parking brake cable mounting bolt (Behind the
back plate).10. Install parking brake assembly, refer to Parking
Brakes in Brake section.
11. Install antilock brake system sensor.
12. Install brake disc.
13. Install brake caliper, refer to Disk 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.

4A2A–10
DIFFERENTIAL (REAR 220mm)
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.

DIFFERENTIAL (REAR 220mm)
4A2A–11
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.

4A2A–12
DIFFERENTIAL (REAR 220mm)
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 64Nꞏm (6.5kgꞏm/47lb 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)

DIFFERENTIAL (REAR 220mm)
4A2A–13
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–15
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

4A2A–16
DIFFERENTIAL (REAR 220mm)
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

DIFFERENTIAL (REAR 220mm)
4A2A–19
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.

DIFFERENTIAL (REAR 220mm)
4A2A–25
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

4A2A–30
DIFFERENTIAL (REAR 220mm)
Pressure ring
425RY003
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
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.