Opel Frontera UBS. Service manual — part 2001
4C–28
DRIVE SHAFT SYSTEM
Shift On The Fly System
Shift On The Fly System and Associated Parts
412RW004
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.
412RW017
8. Take out inner shaft from front axle case.
9. Remove snap ring from inner shaft by using snap ring
pliers.
412RW016
10. Remove inner shaft bearing by using a remover
5–8840–2197–0 and press.
NOTE: Be careful not to damage the shaft.
412RW015
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.
412RS045
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.
412RW014
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.
420RS008
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.
412RS026
Inner Shaft Bearing
412RW006
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
412RW011
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.
412RW022
Clutch Gear Condition
Check and see that there is no wear, damage, cracking,
or any other abnormality in the clutch gear.
Clutch Gear Function
412RW010
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.
412RW009
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