differential OPEL FRONTERA 1998 Manual Online

4A2B–14DIFFERENTIAL (REAR 244mm)
4. Set the dial indicator 5–8840–0126–0 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 od 0.085
7. Record the pinion depth code on the head of the
drive pinion. The number indicates a necessary
change in the pinion mounting distance. A plus
number indicates the need for a greater mounting
distance (which can be achieved by decreasing
the shim thickness). A minus number indicates
the need for a smaller mounting distance (which
can be achieved by increasing the shim
thickness). If examination reveals pinion depth
code “0”, the pinion is “nominal”.
425RS023

DIFFERENTIAL (REAR 244mm)
4A2B–15
8. Select the shim thickness using the chart;
Pinion marking+3+2+10–1–2–3
Dial indicator read-
ing (Inches)(Inches)(Inches)(Inches)(Inches)(Inches)(Inches)(Inches)
0.0240.027
0.0250.0270.028
0.0260.0270.0280.029
0.0270.0270.0280.0290.030
0.0280.0270.0280.0290.0300.031
0.0290.0270.0280.0290.0300.0310.032
0.0300.0270.0280.0290.0300.0310.0320.033
0.0310.0280.0290.0300.0310.0320.0330.034
0.0320.0290.0300.0310.0320.0330.0340.035
0.0330.0300.0310.0320.0330.0340.0350.036
0.0340.0310.0320.0330.0340.0350.0360.037
0.0350.0320.0330.0340.0350.0360.0370.038
0.0360.0330.0340.0350.0360.0370.0380.039
0.0370.0340.0350.0360.0370.0380.0390.040
0.0380.0350.0360.0370.0380.0390.0400.041
0.0390.0360.0370.0380.0390.0400.0410.042
0.0400.0370.0380.0390.0400.0410.0420.043
0.0410.0380.0390.0400.0410.0420.0430.044
0.0420.0390.0400.0410.0420.0430.0440.045
0.0430.0400.0410.0420.0430.0440.0450.046
0.0440.0410.0420.0430.0440.0450.0460.047
0.0450.0420.0430.0440.0450.0460.0470.048
0.0460.0430.0440.0450.0460.0470.0480.049
0.0470.0440.0450.0460.0470.0480.0490.050
0.0480.0450.0460.0470.0480.0490.0500.051
0.0490.0460.0470.0480.0490.0500.0510.052
0.0500.0470.0480.0490.0500.0510.0520.053
0.0510.0480.0490.0500.0510.0520.0530.054
0.0520.0490.0500.0510.0520.0530.0540.055
0.0530.0500.0510.0520.0530.0540.0550.056
0.0540.0510.0520.0530.0540.0550.0560.057
0.0550.0520.0530.0540.0550.0560.0570.058
0.0560.0530.0540.0550.0560.0570.0580.059
0.0570.0540.0550.0560.0570.0580.0590.060
0.0580.0550.0560.0570.0580.0590.0600.061
0.0590.0560.0570.0580.0590.0600.0610.062
0.0600.0570.0580.0590.0600.0610.0620.063
0.0610.0580.0590.0600.0610.0620.0630.064
0.0620.0590.0600.0610.0620.0630.0640.065
0.0630.0600.0610.0620.0630.0640.065
0.0640.0610.0620.0630.0640.065
0.0650.0620.0630.0640.065
0.0660.0630.0640.065
0.0670.0640.065
0.0680.065

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–17
4. Using punch 5–8840–2293–0, stake the flange
nut at two points.
NOTE: When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3).
425RW062
11. Adjust ring gear backlash.
1. Attach the side bearing to the differential
assembly without shims by using installer
5–8840–2570–0 and grip 5–8840–0007–0.
425RW063
2. Insert the differential cage assembly with bearing
outer races into the side bearing bores of the
carrier.
425RS030
3. Using two sets of feeler gauges, insert a feeler
stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
Mount the dial indicator 5–8840–0126–0 on the
carrier so that the indicator stem is at right angles to
a tooth on the ring gear.
425RW049

4A2B–18DIFFERENTIAL (REAR 244mm)
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash: 0.13– 0.2mm (0.005– 0.008in)
425RS032With zero end play and correct backlash
established, remove the feeler gauge packs,
determine the thickness of the shims required and
add 0.05 mm (0.002 in) to each shim pack to
provide side bearing preload. Always use new
shims.
5. Remove side bearing by using remover
5–8840–2587–0 and adapter 5–8840–2576–0.
415RW041
12. Install the side bearings together with the selected
shims by using installer 5–8840–2570–0 (2) and grip
5–8840–0007–0 (1).
425RW032
13. Install side bearing outer race.
14. Install differential cage assembly.
15. Align the setting marks (1) applied at disassembly
then install the bearing cap.
425RS035

DIFFERENTIAL (REAR 244mm)
4A2B–19
16. Tighten the bolt to the specified torque.
Torque:108Nꞏm (11.0kgꞏm/80 lb ft)
425RS036
Gear Tooth Contact Pattern Check and Adjustment
1. Apply a thin coat of Prussian blue or equivalent to the
faces of the 7–8 teeth of the ring gear. Check the
impression of contact on the ring gear teeth and make
necessary adjustment as described in illustration if
the contact is abnormal.
425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)
425RS039

4A2B–20DIFFERENTIAL (REAR 244mm)
Differential Cage Assembly
Disassembled View
415RW010
Legend
(1) Thrust Washer (for Pinion Gear)
(2) Pinion Mate Gear
(3) Thrust Washer(for Side Gear)
(4) Side Gear(5) Differential Shaft
(6) Ring Gear
(7) Bolt
(8) Differention Cage
(9) Lock Pin

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.

4A2B–22DIFFERENTIAL (REAR 244mm)
2. Install the pinion mate gear with thrust washer by
engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.
425RS048
3. Install differential shaft.
1 . B e s u r e t o i n s t a l l t h e d i f f e r e n t i a l s h a f t s o t h a t i t i s i n
alignment with the lock pin hole in the differential
cage.
425RS049
4. Install lock pin.
After lock pin installation, stake the case to secure the
lock pin.
5. Install ring gear.6. Tighten the bolts in diagonal sequence as illustrated.
Torque: 177Nꞏm (18.0kgꞏm/130 lb ft)
NOTE: Discard used bolts and install new ones.
425RW033

DIFFERENTIAL (REAR 244mm)
4A2B–23
Locking Differential Assembly
Disassembled View
425RW027
Legend
(1) Thrust Washer–Differential Pinion Mate Gear
(2) Pinion Mate Gear
(3) Dished Spacer
(4) Disc
(5) Plate
(6) Ring Gear(7) Differential Plate Retainer
(8) Lock Pin
(9) Differential Case
(10) Ring Gear Bolts
(11) Differential Shaft
(12) Differential Side Gear
Disassembly
1. Remove ring gear.
2. Place one of the axle shafts, which was removed from
the assembly, into a vise. Tighten shaft in vise firmly.
The spline end of the shaft is not to exceed 3 inches
(76.2 mm) above the top of the vise.
Position the differential on the shaft with the ring gear
side down.
3. Remove Lock pin (1) from differential shaft using a
punch.