Opel Frontera UBS. Manual - part 1942

DIFFERENTIAL (REAR 220mm) 4A2A–29

Disassembly

Differential Cages A and B

1. To ensure installation of the parts in original position

apply a setting mark before removing the differential
cages A and B.

2. Using special tool, 5–8840–2682–0, grip it with a vice,

and set the differential.

425RS054

3. Gradually and evenly loosen the 3 fixing screws of the

differential cages A and B.

425RS055

4. Remove Differential cage A.
5. Remove Thrust washer. 
6. Remove Spring disc.

NOTE: When removing the spring disc, friction disc, and
friction plate, place them in order for clear distinction of
left and right use.

7. Remove Spring disc.
8. Remove Friction plate.

9. Remove Friction plate.

10. Remove Friction disc.

11. Remove Friction plate.

12. Remove Friction disc.
13. Remove Friction plate.
14. Remove Pressure ring.
15. Remove Side gear.
16. Remove Pinion and pinion shaft.
17. Remove Side gear.
18. Remove Pressure ring.
19. Remove Friction plate.
20. Remove Friction disc.
21. Remove Friction plate.
22. Remove Friction disc.
23. Remove Friction plate.
24. Remove Friction plate.
25. Remove Friction plate.
26. Remove Friction disc.
27. Remove Thrust washer.
28. Remove Differential cage B.

Inspection and Repair

Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is
found through inspection.

Visual check

Check the following parts for wear, damage, noise or any
other abnormal conditions.

D

Friction disc, friction plate and spring disc

425RS056

Legend

(1) Sliding surfaces
(2) Projections

4A2A–30 DIFFERENTIAL (REAR 220mm)

D

Pressure ring

425RY003

Legend

(3) Sliding surface with the friction disc. When

nicks or scratches are found, polish with an oil
stone and repair on a level block using a
compound.

(4) Sliding spherical surface with the pinion gear.
(5) Sliding surface with the side gear.
(6) V–shaped groove of the pressure ring and V

–shaped section of the pinion shaft.

(7) Fitting section with the case.
(8) Face contacting the inner surface of the

differential case. Repair burrs and nicks using
an oil stone. 

D

Thrust washer

425RS058

Legend

(9) Sliding surface with the side gear or case.

(10) Peripheral groove of the side gear.

Repair light nicks and burrs using an oil stone.

D

Case

425RS059

Legend

(11) Contact surface with the spring disc.

(12) Inner groove of the differential cage B.

Repair light nicks and burrs using an oil stone.

425RS060

Legend

(7) Fitting section with the case.
(8) Face contacting the inner surface of the

differential case.

Repair burrs and nicks using an oil stone.

(9) Sliding surface with the side gear or case.

(11) Contact surface with spring disc.

DIFFERENTIAL (REAR 220mm) 4A2A–31

Measure the Deformation of the friction disc & plate.

Limit: 0.1 mm (0.004 in)

425RS061

Measure the wear of the friction plate & disc

Limit(A–B): 0.1 mm (0.004 in)

Remarks:
A=Inner or outer projections
B=Sliding surface subjected to abrasion

425RS062

Measure the wear of the thrust washer

Limit: 1.3 mm (0.05 in)

425RS063

Reassembly

Adjust the clearance between the friction disc and plate.

1. Measuring the depth of the differential cage.

Standard (A–B):

89.13 mm (3.51 in)

(C):

9.13 mm (0.36 in)

425RS064

4A2A–32 DIFFERENTIAL (REAR 220mm)

2. Measuring the overall length of the pressurering,

friction disc and friction plate.

D

Mount the pinion shaft in the pressurering and then
install the friction disc & plate.

D

Measure the length between the plates over the
V–groove. (D)

425RS065

3. After measuring dimensions A,B,C and D, make

adjustment in the following manner:

D

Measure the thickness (E) of the spring disc.
1.75mm (0.069in)

×

2 discs

4. Select the friction disc & plate so as to satisfy the

following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.

Thickness
:1.65–1.75–1.85mm(0.065–0.069–0.073 in)

Backlash adjustment of the side gear in
the direction of the shaft

1. Measuring the depth of the differential cage. 

(F–B): 95.63 mm (3.76 in)

(G): 15.63 mm (0.62 in)

425RS066

2. Measuring the dimension between the thrust washers

at both ends.

D

Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.

D

Have the side gear contact to the pinion to make the
backlash 0. 

D

Measure the dimension  (H) between thrust
washers at both ends.

425RS067