Opel Frontera UBS. Manual - part 1001

4A2B–20

DIFFERENTIAL (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.

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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.

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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.

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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 N·m (11–16kg·cm/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 N·m (30.4–38.8kg·m/220–281 Ib ft).

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DIFFERENTIAL (REAR 244mm) 4A2B–21

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).

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11. Adjust ring gear backlash.

1. Attach the side bearing to the differential

assembly without shims by using installer
5–8840–2050–0 and grip 5–8840–0007–0.

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2. Insert the differential cage assembly with bearing

outer races into the side bearing bores of the
carrier.

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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.

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4A2B–22

DIFFERENTIAL (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)

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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. Remove side bearing by using remover

5–8840–2587–0 and adapter  5–8840–2576–0.

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12. Install the side bearings together with the selected

shims by using installer 5–8840–2050–0 (2) and grip
5–8840–0007–0 (1).

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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.

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DIFFERENTIAL (REAR 244mm) 4A2B–23

16. Tighten the bolt to the specified torque.

Torque:108N·m (11.0kg·m/80 lb ft)

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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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Legend

(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)

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