Differential assembly (Opel Kadett E)

Clean the parts from dirt, check their condition and lubricate thoroughly with gearbox oil.

Install the satellites into the differential box using the KM 160 4 jig, having first put the thrust washers in place.

Install the axle gears together with the thrust washers by turning them in the differential box.

Put the satellite axle back in place and secure it with the locking bolt.

Heat the new speedometer drive pinion to 80°C and install it on the differential box so that the pinion projections fit into the differential box grooves. Use the KM 525 device to facilitate installation of the pinion.

Lubricate the speedometer drive gear teeth with bearing grease.

Heat the differential driven gear to 80°C, monitoring the heating temperature with a thermochromic pencil. Press it onto the differential box and secure with new bolts.

Press the inner rings of the tapered roller bearings onto the differential box using the KM 522 certificate.

Press the outer rings into the adjusting nut and flange

Install new sealing rings on the flange and adjusting nut. Replace the differential box bearing flange and tighten its mounting bolts.



Apply protective grease to the thread of the adjusting nut. Tighten the adjusting nut using the KM 520 tool.



When reusing parts, tighten the adjusting nut to align the marks made during disassembly and obtain a torque of resistance to bearing rotation within 6-10 kgf·m. For new bearings, the torque of resistance to rotation should be within 17-19 kgf·m at a rotation speed of 1 rpm. After installing the gearbox housing and differential, ensure that the torque of resistance to bearing rotation is within 17-19 kgf·m for new bearings and 8 kgf·m for used bearings.





Lock the adjusting nut by bending the tabs of the locking plate.

[Material copied from this portal: OpelBook.ru]

Install the plug into the adjusting nut and into the gearbox housing.

Apply bearing grease to the differential cover gasket, secure it to the cover with grease, install the differential cover and secure it with new bolts.

Note. In the differential of the F20 type gearbox, the satellite axis is locked with a pin, not a bolt, as in the differential of the F16 type gearbox. The thrust washers of the half-axle gears are installed with the support surface of the larger diameter towards the gear. The KM 524 A mandrel is used to center the half-axle gears.