Front axle — removal, installation and repair (Opel Frontera A)

To perform the following tasks, raise and support the front of the vehicle on stands. Mark the position of the wheels relative to the hubs and remove the wheels by unscrewing the mounting bolts.

Differential housing seal

1. Place a container under the gearbox housing, unscrew the drain plug and drain the oil.

2. Remove the gearbox housing as described below.

3. Thoroughly clean the mating surfaces of the crankcase and axle housing and lubricate them with sealant.

4. Reinstall the gearbox housing (see below).

Removal and installation the gearbox housing

1. Place a container under the bridge, unscrew the drain plug and drain the oil.

2. Remove the bridge and drives as described separately.

3. Loosen the bolts and disconnect the gearbox housing from the axle shaft housing

4. Collect the leaking oil in a container.

5. Thoroughly clean the mating surfaces of the crankcase and axle shaft housing.

6. Lubricate them with sealant.

7. Insert the gearbox housing into the axle shaft housing.

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8. Secure it with bolts. For three-door models (the bridge is designated 9HU) tighten the mounting bolts to 28 Nm. For five-door models (bridge designation 12HU) torque of 54 Nm.

9. Install the bridge and drives as described below.

10. Fill the front axle with oil up to the lower edge of the hole.

Replacing the oil seal

In order not to disturb the gearbox adjustments, before unscrewing the drive gear fastening nut, it is necessary to measure its rotation torque using a dynamometer. Since it is easy to overtighten the nut in question when installing the drive flange of the pinion gear and thereby damage the gearbox, it is recommended to have the seal replaced at a car repair shop. The seal is replaced when leaks appear.

Removal and installation the front axle

Removal

1. Remove the four bolts and nuts securing the front suspension crossmember.

2. Disconnect the front propeller shaft from the pinion flange.

3. Remove both front control arms together with the wheel hub and steering knuckle as described above.

4. To do this, disconnect the suspension assembly at the suspension arms in the area where the ball joints are located.

5. Disconnect the central ball joints from the steering link arm and from the intermediate arm using a puller.

6. Place a garage lift under the center of the axle and disconnect the axle from the chassis. At the rear, bolts and washers are used to secure the bridge, while at the front, bolts, nuts and washers are used.



7. Slowly lower the bridge onto the lift and roll it out.

If necessary, the suspension bushings can be pressed out and replaced.

Installation

The bridge is installed in the reverse order of removal.

1. Tighten the bolts and mounting bolts/nuts to a torque of 152 Nm.

2. Steering knuckles, wishbones, etc. are installed in accordance with the above instructions.

3. Tighten the suspension cross member mounting bolts shown in the illustration to a torque of 75 Nm.

4. Finally, check the oil level in the gearbox housing and top up if necessary.

Repair of the main gear

Repair of the main transmission must be carried out in a car repair shop. Since the repaired differential is installed in place without any adjustments, only the main gear can be submitted for repair.