Opel Frontera UE. Manual - part 699

DRIVE SHAFT SYSTEM

4C–15

6. Remove clutch gear.

7. Remove snap ring from front axle case by using 

snap ring pliers.

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8. Take out inner shaft from front axle case.

9. Remove snap ring from inner shaft by using snap 

ring pliers.

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10. Remove inner shaft bearing.

NOTE:  Be careful not to damage the shaft.

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11. Remove needle bearing from inner shaft by using a 

remover 5–8840–0027–0 and sliding hammer 5–
8840–0084–0.

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12. Remove oil seal from front axle case.

NOTE:  Be careful not to damage the front axle case.

4C–16

DRIVE SHAFT SYSTEM

Inspection And Repair

Inspect the removed parts. If there are abnormalities 
such as wear and damage, take corrective action or 
replace.

Visual Check

1. Check and see if the inner shaft has such 

abnormalities as wear and damage.

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2. When inspecting the inner shaft, be sure to check 

and see if its splined part is twisted, worn, or 
cracked. If so, replace with a new shaft. In case 
such an abnormality in its gear part  (a slide with 
sleeve), replace the shaft.

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Inner Shaft Run–Out

With both end centers supported, rotate the shaft slowly 
and measure deflection with a dial gauge.

Limit:0.5mm (0.02in)

NOTE:  Do not heat the shaft to correct its bend.

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Inner Shaft Bearing

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Legend

EndOFCallout

1. Inspect the state of inner shaft bearing. If any 

abnormality such as smoothlessness is found, 
replace with a new inner shaft bearing.

2. Insert a clutch gear and check the state of needle 

bearing.

3. If there is an abnormality such as smoothlessness, 

replace the needle bearing.

(1) Inner Shaft Bearing
(2) Inner Shaft
(3) Clutch Gear

DRIVE SHAFT SYSTEM

4C–17

Sleeve Condition

Check and see that there is not 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

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Operate the sleeve with the inner shaft combined with 
the clutch gear and if smoothlessness 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:7.1mm (1.28in)

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Clutch Gear Condition

Check and see that there is not wear, damage, crack, or 
any other abnormality in the clutch gear.

Clutch Gear Function

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If 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:36.98mm (1.456in)

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4C–18

DRIVE SHAFT SYSTEM

Actuator

Check and see that there is no damage, cracking, or 
other abnormality.
Functional Check

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Disconnect the shift position switch and make sure of 
function with a vacuum of –400 mmHg applied to Ports 
A and B, in accordance with the table below.

If there is an abnormality, replace the actuator as an 
assembly.

NOTE:

1. If the actuator works under –400mmHg or less, 

there is no functional problem.

2. Be careful not to permit the entry of water or dust 

into the ports of the actuator.

Dimentional Check

Measure illustrated sizes 1, 2, and 3.

Limit

1=64.1mm (2.52in)

2=6.7 mm (0.26 in)

3=6.7 mm (0.26 in)

State

Port A

Port B

Function

C

–400 mmHg

A/P

E

D

A/P

–400 mmHg

F