Opel Frontera UBS. Manual - part 983

4A1–15

DIFFERENTIAL (FRONT)

8. Select the shim using the chart;

Pinion marking

+10

+8

+6

+4

+2

0

–2

–4

–6

–8

–10

Dial indicator
reading 
(Inches)

mm

 (Inches)

mm

 (Inches)

mm

 (Inches)

mm

 (Inches)

mm

 (Inches)

mm

 (Inches)

mm

 (Inches)

mm

 (Inches)

mm

 (Inches)

mm

 (Inches)

mm

 (Inches)

0.081

2.18

(0.0858)

0.082

2.18

(0.0858)

2.20

(0.0866)

0.083

2.18

(0.0858)

2.20

(0.0866)

2.23

(0.0882)

0.084

2.18

(0.0858)

2.20

(0.0866)

2.24

(0.0882)

2.26

(0.0890)

0.085

2.18

(0.0858)

2.20

(0.0866)

2.24

(0.0882)

2.26

(0.0890)

2.28

(0.0898)

0.086

2.18

(0.0858)

2.20

(0.0866)

2.24

(0.0882)

2.26

(0.0890)

2.28

(0.0898)

2.32

(0.0914)

0.087

2.18

(0.0858)

2.20

(0.0866)

2.24

(0.0882)

2.26

(0.0890)

2.28

(0.0898)

2.32

(0.0914)

2.34

(0.0921)

0.088

2.18

(0.0858)

2.20

(0.0866)

2.24

(0.0882)

2.26

(0.0890)

2.28

(0.0898)

2.32

(0.0914)

2.34

(0.0921)

2.36

(0.0929)

0.089

2.18

(0.0858)

2.20

(0.0866)

2.24

(0.0882)

2.26

(0.0890)

2.28

(0.0898)

2.32

(0.0914)

2.34

(0.0921)

2.36

(0.0929)

2.38

(0.0937)

0.090

2.18

(0.0858)

2.20

(0.0866)

2.24

(0.0882)

2.26

(0.0890)

2.28

(0.0898)

2.32

(0.0914)

2.34

(0.0921)

2.36

(0.0929)

2.38

(0.0937)

2.42

(0.0953)

0.091

2.18

(0.0858)

2.20

(0.0866)

2.24

(0.0882)

2.26

(0.0890)

2.28

(0.0898)

2.32

(0.0914)

2.34

(0.0921)

2.36

(0.0929)

2.38

(0.0937)

2.42

(0.0953)

2.44

(0.0961)

0.092

2.20

(0.0866)

2.24

(0.0882)

2.26

(0.0890)

2.28

(0.0898)

2.32

(0.0914)

2.34

(0.0921)

2.36

(0.0929)

2.38

(0.0937)

2.42

(0.0953)

2.44

(0.0961)

2.46

(0.0969)

0.093

2.24

(0.0882)

2.26

(0.0890)

2.28

(0.0898)

2.32

(0.0914)

2.34

(0.0921)

2.36

(0.0929)

2.38

(0.0937)

2.42

(0.0953)

2.44

(0.0961)

2.46

(0.0969)

2.48

(0.0977)

0.094

2.26

(0.0890)

2.28

(0.0898)

2.32

(0.0914)

2.34

(0.0921)

2.36

(0.0929)

2.38

(0.0937)

2.42

(0.0953)

2.44

(0.0961)

2.46

(0.0969)

2.48

(0.0977)

2.52

(0.0992)

0.095

2.28

(0.0898)

2.32

(0.0914)

2.34

(0.0921)

2.36

(0.0929)

2.38

(0.0937)

2.42

(0.0953)

2.44

(0.0961)

2.46

(0.0969)

2.48

(0.0977)

2.52

(0.0992)

2.54

(0.1000)

0.096

2.32

(0.0914)

2.34

(0.0921)

2.36

(0.0929)

2.38

(0.0937)

2.42

(0.0953)

2.44

(0.0961)

2.46

(0.0969)

2.48

(0.0977)

2.52

(0.0992)

2.54

(0.1000)

2.56

(0.1008)

0.097

2.34

(0.0921)

2.36

(0.0929)

2.38

(0.0937)

2.42

(0.0953)

2.44

(0.0961)

2.46

(0.0969)

2.48

(0.0977)

2.52

(0.0992)

2.54

(0.1000)

2.56

(0.1008)

0.098

2.36

(0.0929)

2.38

(0.0937)

2.42

(0.0953)

2.44

(0.0961)

2.46

(0.0969)

2.48

(0.0977)

2.52

(0.0992)

2.54

(0.1000)

2.56

(0.1008)

0.099

2.38

(0.0937)

2.42

(0.0953)

2.44

(0.0961)

2.46

(0.0969)

2.48

(0.0977)

2.52

(0.0992)

2.54

(0.1000)

2.56

(0.1008)

0

2.42

(0.0953)

2.44

(0.0961)

2.46

(0.0969)

2.48

(0.0977)

2.52

(0.0992)

2.54

(0.1000)

2.56

(0.1008)

0.001

2.44

(0.0961)

2.46

(0.0969)

2.48

(0.0977)

2.52

(0.0992)

2.54

(0.1000)

2.56

(0.1008)

0.002

2.46

(0.0969)

2.48

(0.0977)

2.52

(0.0992)

2.54

(0.1000)

2.56

(0.1008)

0.003

2.48

(0.0977)

2.52

(0.0992)

2.54

(0.1000)

2.56

(0.1008)

0.004

2.52

(0.0992)

2.54

(0.1000)

2.56

(0.1008)

0.005

2.54

(0.1000)

2.56

(0.1008)

0.006

2.56

(0.1008)

NOTE: When ordering shims, find the part number in the
parts catalog by using the thickness of shims listed in the
above table.

4. Place the shim on the drive pinion, with the chamfered

side turned towards the pinion head then install the
inner bearing onto the pinion using an installer
9–8522–1165–0 and a press.

DIFFERENTIAL (FRONT)

4A1–16

NOTE: Do not apply pressure to the roller cage and apply
pressure only to the inner race.

425RW048

5. Discard the used collapsible spacer and install a new

one.

6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer 9–8522–1275–0 to install a new

oil seal that has been soaked in rear axle lubricant.

NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.

415RW024

9. Install dust cover.

10. Install flange.

11. Install flange nut.

1. Apply lubricant to the pinion threads.

2. Tighten the nut to the specified torque using the

pinion flange holder 5–8840–2157–0.

Torque: 177–275N·m (18–28kg·m/130–203 lb ft)

NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.

425RW047

3. Adjust pinion bearing preload.

a. Measure the bearing preload by using a torque

meter. Note the scale reading required to
rotate the flange.

b. Continue tightening flange nut until the

specified starting torque is obtained.

Starting torque:
New bearing
0.7–1.1 N·m(0.065–0.115kg·m/5.64–9.98 lb in)
Used bearing
0.4–0.5N·m(0.033–0.057kg·m/2.86–4.94 Ib in)

425RS027

4. Using punch 5-8840-2293-0, stake the flange nut

at two points.

4A1–17

DIFFERENTIAL (FRONT)

NOTE: When staking, be sure to turn the nut to insure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3).

415RW019

Legend

(1) 1.3mm or less

12. Install adjust shim.

1. Attach the side bearing to the differential

assembly without shims. Support the opposite
side using a pilot to prevent bearing damage.

425RS029

Legend

(1) Drive handle:5–8840–0007–0
(2) Installer:9–8522–1164–0
(3) Pilot:9–8521–1743–0

2. Insert the differential cage assembly with bearing

outer races into the side bearing bores of the
carrier.

425RS030

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.

425RW049

DIFFERENTIAL (FRONT)

4A1–18

4. Adjust feeler gauge thickness from side to side

until ring gear backlash is in the specified range.

Backlash: 0.13–0.18 mm(0.005 –0.007 in)

425RS032

With zero end play and correct backlash estab-
lished, 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. Use bearing remover 5–8840–0013–0 and

5–8840–0014–0 and pilot 9–8521–1743–0 to
remove side bearing.

415RW020

13. Install the side bearings together with the selected

shims.

425RS029

Legend

(1) Drive Handle:5–8840–0007–0
(2) Installer: 9–8522–1164–0
(3) Pilot: 9–8521–1743–0

14. Install side bearing outer race.
15. Install differential cage assembly.
16. Install bearing cap then align the setting marks(1)

applied at disassembly.

425RS035