Opel Frontera UBS. Manual - part 2001

4C–28

DRIVE SHAFT SYSTEM

Shift On The Fly System

Shift On The Fly System and Associated Parts

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Legend

(1) Filler Plug
(2) Bolt
(3) Oil Seal
(4) Snap Ring(External)
(5) Inner Shaft Bearing
(6) Snap Ring(Internal)
(7) Inner Shaft

(8) Needle Bearing
(9) Clutch Gear

(10) Sleeve

(11) Housing

(12) Front Axle Drive Shaft (LH side)with Bracket
(13) Bolt
(14) Actuator Assembly
(15) Bolt

Disassembly

1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove

front axle drive shaft from front axle case.

3. Remove Actuator Assembly and draw out actuator

ASM.

4. Remove housing.
5. Remove sleeve.
6. Remove clutch gear.

4C–29

DRIVE SHAFT SYSTEM

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 by using a remover

5–8840–2197–0 and press.

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.

NOTE: Be careful not to damage the shaft.

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12. Remove oil seal from front axle case.

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

4C–30

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 any

abnormalities such 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 of 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: 0.5 mm (0.02 in)max.

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

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Inner Shaft Bearing

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Legend

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

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

abnormality such as roughness 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 roughness, replace

the needle bearing.

4C–31

DRIVE SHAFT SYSTEM

Sleeve Condition

Check and see that there is no 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. If roughness 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: 7.1 mm (0.28 in) max.

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Clutch Gear Condition

Check and see that there is no wear, damage, cracking,
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: 36.98 mm (1.456 in) min.

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