Opel Frontera UBS. Manual - part 2002

4C–32

DRIVE SHAFT SYSTEM

Actuator

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

Functional Check

412RW021

412RW013

412RW007

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.

State

Port A

Port B

Function

C

–400 mmHg

A/P

E

D

A/P

–400 mmHg

F

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.

Dimensional Check 
Measure illustrated sizes 1, 2, and 3.

Limit
1=64.3 mm (2.53 in) max.
2=6.7 mm (0.26 in) min.
3=6.7 mm (0.26 in) min.

4C–33

DRIVE SHAFT SYSTEM

412RS037

Reassembly

1. Install the new oil seal which has been immersed in

differential gear oil, by using an oil seal installer
5–8840–2407–0 and grip 5–8840–0007–0.

412RS043

2. Force a new needle bearing into inner shaft by using a

installer 5–8840–2408–0 and grip 5–8840–0007–0.

412RS051

3. Place a new snap ring(internal) in inner shaft. 

Force a new inner shaft bearing into the inner shaft by
using a installer 5–8840–2197–0 and press.

412RS044

4. Install snap ring(external).

NOTE: Be careful not to damage the inner shaft.

5. Clean the housing contact surface of the front axle

case and insert inner shaft assembly into the front
axle case.

4C–34

DRIVE SHAFT SYSTEM

NOTE: Be careful not to damage seal.

6. Install snap ring (internal) in the groove of front axle

case.

NOTE: Be sure to install the snap ring properly.

412RW017

7. Apply differential gear oil to clutch gear, then install

clutch gear.

8. Apply differential gear oil to sleeve, then install

sleeve.

9. Clean contact surface with the front axle and actuator

mounting surface. Apply liquid gasket  to the contact
surface on the front axle case, then install in the
housing.

412RW023

10. Tighten bolts to specified torque.

Torque: 116N·m (11.8 kg·m/85 lb ft)

11. Clean the actuator contact surface with the housing

then Install and tighten shift position switch to
specified torque.

Torque: 39N·m (4.0 kg·m/29 lb ft)

12. Apply liquid gasket to the contact surface on the

actuator side.

412RW012

13. Align shift arm with the groove of sleeve and install the

actuator.

14. Tighten bolts to specified torque.

Torque: 13N·m (1.3 kg·m/113 lb in)

15. Install front axle drive shaft and mounting bracket.

Tighten fitting bolts to specified  torque.

Torque: 116N·m (11.8 kg·m/85 lb ft)

16. Pour specified amount of differential gear oil to filler

plug.

Front Differential

Oil Capacity: 1.4lit (1.23 Imp qt/1.48 US qt)

Actuator Housing

Oil Capacity: 0.12lit (0.10 Imp qt/0.13 US qt)

17. Install filler plug through gasket and tighten to

specified torque.

Torque: 78N·m (58lb ft)

4C–35

DRIVE SHAFT SYSTEM

Main Data and Specifications

General Specifications

Front drive axle oil capacity

1.4 liter (1.23 Imp qt/1.48 US qt)(Differential)

0.12 liter (0.10 Imp qt/0.13 US qt)(Actuator Housing:Shift on the fly)

Type of lubricant

GL–5 (Multi grade type) Refer to chart in General Information

Axle shaft type

Constant velocity joint(Birfield joint type and double offset joint)

Torque Specifications

E04RW020