Opel Frontera UE. Manual - part 677

 

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Opel Frontera UE. Manual - part 677

 

 

4A1–14

DIFFERENTIAL (FRONT)

4. Place the shim on the drive pinion. 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.

425RW067

5. Discard the used collapsible spacer and install a 

new one.

6. Install pinion gear.

7. Install outer bearing.

8. Use oil seal installer 9–8522–1275–0 to install a 

new oil seal that has been soaked in front axle 
lubricant.

NOTE:  Take care to use a front differential oil seal, NOT 
the rear differential oil seal.

415RW024

9. Install duct 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:177-275 N·m(18-28kg·m/130-203lbft)

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 bearing:0.7–1.1N·m(6.5–11.5kg·cm/5.6–
10lbin)

Used bearing:0.4–0.5N·m(3.3–5.7kg·cm/2.9–
5.0 lbin)

DIFFERENTIAL (FRONT)

4A1–15

425RS027

4. Using punch 5–8840–2293–0, stake the flange 

nut at two points.

NOTE:  When staking, be sure to turn the nut to insure 
that there is no change in bearing preload. Make sure of 
preload again as instructed in 3)

415RW019

Legend

EndOFCallout

12. Install adjust shim.

1. Attach the side bearing to the differential 

assembly without shims. Support the opposite 
side using a pilot to prevent bearing damage.

425RS029

Legend

EndOFCallout

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.

(1) 1.3mm or less

(1) Drive handle:5–8840–0007–0
(2) Installer:9–8522–1164–0
(3) Pilot:9–8521–1743–0

4A1–16

DIFFERENTIAL (FRONT)

425RS031

4. Adjust feeler gauge thickness from side to side 

until ring gear backlash is in the specified range.

Backlash:0.13–0.18mm(0.005 –0.007in)

425RS032

With 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. Use bearing remover 5–8840–0013–0, 5–8840–

0014–0 and pilot 9–8521–1743–0 to remove 
side bearing.

415RW020

13. Install the side bearings together with the selected 

shims.

425RS029

Legend

EndOFCallout

(1) Drive Handle:5–8840–0007–0
(2) Installer: 9–8522–1164–0
(3) Pilot: 9–8521–1743–0

DIFFERENTIAL (FRONT)

4A1–17

14. Install side bearing outer race.

15. Install differential cage assembly.

16. Install bearing cap then align the setting marks(1) 

applied at disassembly.

425RS035

17. Tighten the cap  bolt to the specified torque.

Torque:98N·m (10kg·m/72 lbft)

425RS036

1. Measure the amount of run-out of the ring gear 

at its rear face.

Standard: 0.02 mm (0.001 in)

Limit: 0.05 mm (0.002 in)

425RS037

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.

 

 

 

 

 

 

 

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