oil OPEL FRONTERA 1998 Manual Online

4C–21 DRIVE SHAFT SYSTEM
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2117–0
(J–36827)
Wrench; Hub nut
5–8840–2119–0
(J–36829)
Installer; Inner bearing
5–8840–2118–0
(J–36828)
Installer; Outer bearing
5–8840–2120–0
(J–36830)
Installer; Oil seal
5–8840–0007–0
(J–8092)
Grip

4C–22
DRIVE SHAFT SYSTEM
Front Drive Shaft Joint
Front Drive Shaft Joints Replace-
ment
Refer to Front Drive Axle Assembly Replacement in
this section, and refer to Front Hub and Disc in
Suspension section.
Front Hub Bearing Preload Check
Check the hub bearing preload at the wheel pin.
New bearing and New oil seal
Preload: 20 – 25 N (2.0 – 2.5 kg/4.4–5.5 lb)
New bearing and New oil seal
Preload: 12 –18 N (1.2 – 1.8 kg/2.6–4.0 lb)
411RS001
Inspection Of Shift On The Fly System
Gear Oil
412RT002
1. Open filler plug and make sure that the oil is up to the
plug port.
If the level oil is low, replenish with gear oil GL–5
grade.
2. Tighten the filler plug to specified torque.
Torque: 7.8 Nꞏm (7.9 kgꞏcm/58 lb in)

4C–23 DRIVE SHAFT SYSTEM
Front Axle Drive Shaft
Front Axle Drive Shaft and Associated Parts
This illustration is based on the model equipped with shift on the fly system.
412RW003
Legend
(1) Axle Case and Differential
(2) DOJ Case Assembly
(3) Snap Ring
(4) Bearing
(5) Snap Ring
(6) Oil Seal
(7) Bracket
(8) DOJ Case
(9) Circlip
(10) Bolt
(11) Drive Shaft Joint Assembly
(12) Snap Ring(13) Spacer
(14) Ball
(15) Snap Ring
(16) Ball Retainer
(17) Ball Guide
(18) Band
(19) Bellows
(20) Band
(21) Band
(22) Bellows
(23) Band
(24) BJ Shaft
(25) Dust Seal

4C–25 DRIVE SHAFT SYSTEM
8. Using snap ring pliers, remove the snap ring (1)
fastening the ball retainer to the center shaft.
412RS013
9. Remove ball retainer, ball guide and bellows.
10. Raise the hooked end of the band (1) with a
screwdriver or equivalent.
412RS014
11. Remove band.
12. Remove bellows.
13. Remove dust seal.
14. Remove BJ shaft assembly.
15. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
16. Remove snap ring and bearing.
17. Remove snap ring and oil seal.
18. Remove bracket.
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. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal
Bushing Replacement
Remove the bushings using a remover
5–8840–2309–0 and hammer.
412RW051
By using installer and base 5–8840–2309–0, press fit
the bushings into the bracket.
412RW052

4C–26
DRIVE SHAFT SYSTEM
Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to
the specified torque.
Torque: 116 Nꞏm (11.8 kgꞏm/85 lb ft)
5. Apply 150g of the specified grease in BJ .
6. Install dust seal .
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
8. Install band. Note the setting direction. After
installation, check that the bellows is free from
distortion.
412RS017
9. Install another bellows and fix band.
10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
12. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
412RS013
13. Align the track on the ball (1) retainer with the window
in the cage, and install the six balls into position.
412RS018
14. Install spacer.
15. Install snap ring.
16. Enclose 150g of the specified grease in DOJ case,
then install drive shaft joint assembly. After
reassembly, move the DOJ longitudinally several
times to get to fit.
17. Install the circlip (1) so that open ends are positioned
away from the ball groove.

4C–28
DRIVE SHAFT SYSTEM
Shift On The Fly System
Shift On The Fly System and Associated Parts
412RW004
Legend
(1) Filler Plug
(2) Bolt
(3) Oil Seal
(4) Snap Ring(External)
(5) Inner Shaft Bearing
(6) Snap Ring(Internal)
(7) Inner Shaft(8) Needle Bearing
(9) Clutch Gear
(10) Sleeve
(11) Housing
(12) Front Axle Drive Shaft (LH side)with Bracket
(13) Bolt
(14) Actuator Assembly
(15) Bolt
Disassembly
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove
front axle drive shaft from front axle case.3. Remove Actuator Assembly and draw out actuator
ASM.
4. Remove housing.
5. Remove sleeve.
6. Remove clutch gear.

4C–29 DRIVE SHAFT SYSTEM
7. Remove snap ring from front axle case by using snap
ring pliers.
412RW017
8. Take out inner shaft from front axle case.
9. Remove snap ring from inner shaft by using snap ring
pliers.
412RW016
10. Remove inner shaft bearing by using a remover
5–8840–2197–0 and press.
NOTE: Be careful not to damage the shaft.
412RW015
11. Remove needle bearing from inner shaft by using a
remover 5–8840–0027–0 and sliding hammer
5–8840–0084–0.
NOTE: Be careful not to damage the shaft.
412RS045
12. Remove oil seal from front axle case.
NOTE: Be careful not to damage the front axle case.

4C–31 DRIVE SHAFT SYSTEM
Sleeve Condition
Check and see that there is no wear, damage, or cracking
in the sleeve.
NOTE: Close inspection of the groove and inner gear are
required because those are important parts.
Sleeve Function
412RW011Operate the sleeve with the inner shaft combined with the
clutch gear. If roughness is felt, replace the sleeve.
NOTE: Gear oil should be applied to the contact surface
of gear.
Check the width of sleeve center groove.
Limit: 7.1 mm (0.28 in) max.
412RW022
Clutch Gear Condition
Check and see that there is no wear, damage, cracking,
or any other abnormality in the clutch gear.
Clutch Gear Function
412RW010If there is an abnormality such as roughness when
operated in combination with sleeve, replace the clutch
gear.
NOTE: When inspecting, gear oil should be applied to the
contact surface of gear.
Clutch Gear Journal Diameter
Make sure of the size illustrated.
Limit: 36.98 mm (1.456 in) min.
412RW009

4C–33 DRIVE SHAFT SYSTEM
412RS037
Reassembly
1. Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer
5–8840–2407–0 and grip 5–8840–0007–0.
412RS043
2. Force a new needle bearing into inner shaft by using a
installer 5–8840–2408–0 and grip 5–8840–0007–0.
412RS051
3. Place a new snap ring(internal) in inner shaft.
Force a new inner shaft bearing into the inner shaft by
using a installer 5–8840–2197–0 and press.
412RS044
4. Install snap ring(external).
NOTE: Be careful not to damage the inner shaft.
5. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.

4C–34
DRIVE SHAFT SYSTEM
NOTE: Be careful not to damage seal.
6. Install snap ring (internal) in the groove of front axle
case.
NOTE: Be sure to install the snap ring properly.
412RW017
7. Apply differential gear oil to clutch gear, then install
clutch gear.
8. Apply differential gear oil to sleeve, then install
sleeve.
9. Clean contact surface with the front axle and actuator
mounting surface. Apply liquid gasket to the contact
surface on the front axle case, then install in the
housing.
412RW023
10. Tighten bolts to specified torque.
Torque: 116Nꞏm (11.8 kgꞏm/85 lb ft)11. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
Torque: 39Nꞏm (4.0 kgꞏm/29 lb ft)
12. Apply liquid gasket to the contact surface on the
actuator side.
412RW012
13. Align shift arm with the groove of sleeve and install the
actuator.
14. Tighten bolts to specified torque.
Torque: 13Nꞏm (1.3 kgꞏm/113 lb in)
15. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
Torque: 116Nꞏm (11.8 kgꞏm/85 lb ft)
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.4lit (1.23 Imp qt/1.48 US qt)
Actuator Housing
Oil Capacity: 0.12lit (0.10 Imp qt/0.13 US qt)
17. Install filler plug through gasket and tighten to
specified torque.
To r q u e : 7 8 N ꞏm ( 5 8 l b f t )