Differential oil OPEL FRONTERA 1998 Manual Online

4A2A–38
DIFFERENTIAL (REAR 220mm)
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2166–0
(J–23597–7)
Gauge plate
5–8840–0126–0
(J–8001)
Dial indicator
5–8840–2167–0
(J–23597–8)
Disc
5–8840–0128–0
(J–23597–1)
Arbor
9–8522–1165–0
(J–6133–01)
Installer; Pinion bearing
5–8840–2293–0
(J–39209)
Punch; End nut lock
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2162–0
(J–24244)
Installer; Side bearing
5–8840–2323–0
(J–39602)
Remover; Outer bearing
5–8840–2165–0
(J–37263)
Installer; Pinion oil seal
5–8840–2682–0
(J–44450)
Holder; Side gear
5–8840–0129–0
(J–23597–12)
Rear pilot

DIFFERENTIAL (REAR 244mm)
4A2B–1
DRIVELINE/AXLE
DIFFERENTIAL (REAR 244mm)
CONTENTS
Service Precaution 4A2B–1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2B–3. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2B–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2B–5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2B–5. . . . . .
Removal 4A2B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2B–6. . . . . . . . . . . . . . . . . .
Installation 4A2B–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shaft 4A2B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shaft and Associated Parts 4A2B–7. . . . . . . . .
Removal 4A2B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–8. . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2B–9. . . . . . . . . . . . . . . . . .
Installation 4A2B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2B–10. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2B–10. . . . .
Removal 4A2B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–11. . . . . . . . . . . . . . . . . .
Installation 4A2B–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Assembly 4A2B–12. . . . . . . . . . . . . . . . . . . .
Differential Assembly and Associated Parts 4A2B–12
Removal 4A2B–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A2B–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2B–14. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–15. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A2B–17. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A2B–24. . . . . . . . . . . . . . .
Disassembled View 4A2B–24. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–25. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–25. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Slip Differential 4A2B–28. . . . . . . . . . . . . . . . . . .
Disassembled View 4A2B–28. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–29. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–29. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–31. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A2B–35. . . . . . . . . . . . .
Special Tools 4A2B–37. . . . . . . . . . . . . . . . . . . . . . . . . . .
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
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.
The
244 differential has two N types A-type and B-
type.
A-type: the sticker with bar code is attached.
B-type: the sticker with no bar code on the lower part
of carrier is attached.

DIFFERENTIAL (REAR 244mm)
4A2B–5
Axle Housing
Axle Housing and Associated Parts
420RY00007
Legend
(1) Coil Spring and Insulator
(2) Axle Housing Assembly
(3) ABS Speed Sensor and Harness (if so
equipped)
(4) Nut
(5) Parking Brake Cable
(6) Bolt and Nut
(7) Antilock Brake System (ABS) Connector and
Bracket (if so 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 Brakes
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 Brakes section.
7. Move the clip aside and pull out the breather hose.

4A2B–6DIFFERENTIAL (REAR 244mm)
8. Disconnect the ABS connectors (1) and remove the
brackets (2) (if so equipped) attached to the frame
and center link.
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 (if so equipped) on the
axle housing.
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/54 lb ft)
3. Install brake pipe.
4. Connect antilock brake system (ABS) speed sensor
and harness (if so equipped), refer to Anti–Lock
Brake System in Brake section.
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.

4A2B–8DIFFERENTIAL (REAR 244mm)
7.Remove the parking brake cable mounting
bolts(Behind the back plate)(1).
311RS001
8. Remove the bearing holder mounting nuts.
9. Remove axle shaft assembly.
NOTE: Be sure not to damage the oil seal.
10. Remove snap ring.
11. Using a bearing remover 5–8840–2295–0 and press,
remove retainer together with the bearing holder.
420RY00012
12. Remove bearing.
13. Remove bearing holder.
14. Remove back plate.15. Remove the wheel pins using a remover
5–8840–0029–0.
420RY00011
Inspection and Repair
Make necessary correction or parts replacement if wear,
corrosion or any other abnormal conditions are found
through inspection.
Visual Check:
Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Axle shaft
2. Bearing
When checking the axle shaft, pay special attention to the
splined portions and replace the shaft if distortion or step
wear is noticeable. Correct slight step wear with a grinder.
420RS008

DIFFERENTIAL (REAR 244mm)
4A2B–9
Axle Shaft Run–out
Limit: 1.0 mm (0.039 in)
420RS009
Axle Shaft Flange Run–out
Limit: 0.08 mm (0.003 in)
420RS010
Oil Seal Replacement
Remove the oil seal carefully not to damage the bearing
holder bore .
When installing, use oil seal installer 5–8840–2310–0.
420RY00009
Installation
1. Install wheel pin.
2. Install back plate.
3. Install bearing holder.
4. Install bearing.
5. Install retainer by using a bearing installer
5–8840–2296–0, press fit together with the bearing.
420RY00010

4A2B–10DIFFERENTIAL (REAR 244mm)
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
425RY00010
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 244mm)
4A2B–11
3. Remove flange nut and washer by using pinion flange
holder 5–8840–0133–0 after raising up its staked
parts completely.
415RW040
4. Remove flange.
5. Remove oil seal.
6. Remove outer bearing by using remover
5–8840–2323–0.
425RY00003
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.

4A2B–12DIFFERENTIAL (REAR 244mm)
Differential Assembly
Differential Assembly and Associated Parts
425RY00016
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–13
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)