Opel Frontera UE. Manual - part 75

DIFFERENTIAL (FRONT)

4A1–21

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 
condition 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. Discard used bolts and install new ones.

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:108N·m(11.0Kg·m/80lbft)

415RS016

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

4A1–22

DIFFERENTIAL (FRONT)

Clearance between the side gear and the 
differential box:

Standard: 0.03 - 0.10 mm (0.001 - 0.004 in)

Limit: 0.15 mm (0.006 in)

425RS046

Legend

EndOFCallout

Play in splines between the side gear and 
the axle shaft:

Standard: 0.08 - 0.36 mm (0.003 - 0.014 in)

Limit: 0.5 mm (0.02 in)

425RS047

Reassembly

1. Install thrust washer.

2. Install side gear.

3. Install the pinion gear with thrust washer by 

engaging it with the side gears while turning both 
pinion gears simultaneously in the same direction.

425RS048

4. Install cross pin.

1. Be sure to install the cross pin so that it is in 

alignment with the lock pin hole in the differential 
cage.

425RS049

(1) Side Gear
(2) Differential Box

DIFFERENTIAL (FRONT)

4A1–23

2. Adjust the backlash between the side gear and 

the pinion gear.
Backlash: 0.03 - 0.08 mm (0.001 - 0.003 in)
Thickness of thrust washers available:
1.00mm, 1.05 mm, 1.10mm(0.039in, 0.041 in, 
0.043in)

425RS050

5. Install lock pin. After lock pin installation, stake the 

cage to secure the lock pin.

425RS051

Legend

EndOFCallout

6.  Clean the ring gear threaded holes to remove the 

locking agent. When installing the ring gear, apply 
LOCTITE 271 or equivalent to all the threaded area 
and half of the unthreaded area of the bolt.

7. Tighten the bolts in diagonal sequence as 

illustrated.

Torque:108N·m(11.0kg·m/80lbft)

NOTE:  Discard used bolts and install new ones.

415RS016

(1) Staked Portion
(2) Lock Pin

4A1–24

DIFFERENTIAL (FRONT)

Main Data and Specifications

General Specifications

Axle tube Type

It consists of the duct, a cast iron housing and the axle 

tube.

Gear type

Hypoid

Gear ratio

(to 1)

4.100 (6VD1 with A/T)

4.300 (6VD1 with M/T)

4.777 (X22SE with M/T)

Differential type

Two pinion

Oil capacity

liter (US qt)

1.4 (1.5) (Differential)

0.12 (0.13) (Actuator Housing: Shift on the fly)

Type of lubricant

GL–5 (75W–90)

Axle shaft type

Constant velocity joint (Birfield joint type and double offset 

joint)

Hub locking Type

Rigid