check oil OPEL FRONTERA 1998 Workshop Manual

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–73
Check circuitTe r m i n a l
Measuring condition Voltage (V)
+-
Winter lamp C79-12C78-15
or -19Winter lamp ON Less than 1
Winter lamp OFF 8
16
Solenoid S1 C78-4C78-15
or -19OFF (3rd or O/D) Less than 1
ON (1st or 2nd) 8
16
Solenoid S2 C78-3C78-15
or -19OFF (1st or O/D) Less than 1
ON (2nd or 3rd) 8
16
Lock up solenoid SL C78-12C78-15
or -19OFF (Lock up OFF) Less than 1
ON (Lock up ON) 8
16
Pressure control solenoid C78-11 C78-8At throttle pressure changing Less than
1
8-16
Oil temperature sensor C79-18 C79-27ATF temperature 20
C4.70
ATF temperature 80
C3.65
Tech 2 diagnosis terminal
(J1850)C78-6C78-15
or -19On diagnosis communication 0-1.5
6.25-8.0
Throttle position sensor
(ground)C79-19C78-15
or -19Key switch ON
-0.1
0.1

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–75
ON-VEHICLE SERVICE
242RX00001
TRANSIMISSION FLUID LEVEL AND
CONDITION
Park vehicle on level ground and set parking brake.
With the engine idling, move the shift lever through all
positions from "P" to "L", then return to position "P".
Check to see If the level of fluid comes to "HOT" range
of about 80
C (176F) on the dipstick gauge.
If the level of fluid is too low, replenish to bring it to
maximum level in "HOT" range.
Inspection of fluid condition
If the ATF is black or smells burnt, replace it.
ATF REPLACEMENT
NOTE:
Do not overfill.
1) Remove the drain plug from oil pan and drain the
fluid.
2) Reinstall the drain plug securely.
3) With the engine OFF, add new fluid through the filler
tube.
4) Star t the engine and shift the selector into all
position from "P" through "L", and then shift into "P".
5) With the engine idling, check the fluid level. Add fluid
up to the "COLD" level on the dipstick.
6) The ATF level must be checked again for correct
level with the "HOT" level.
NOTE:
To prevent fluid leaks, the drain plug gasket must be
replaced each time this plug is removed.
Tr a n s m i s s i o n
Drain and refill 5.2 L
Dry fill 8.7 L
Fluid BESCO ATF III

7A–78 AUTOMATIC TRANSMISSION (AW30-40LE)
F07RY00019
225RY00001
220RY00001
244RX00001
PATTERN SELECT SWITCH INSPECTION
Inspect that there is continuity between each terminals.
OVERDRIVE OFF SWITCH INSPECTION
Inspect that there is continuity between terminals 2 and 4.
SOLENOID INSPECTION
1. Resistance check
• Using an ohmmeter, check the resistance between each
terminals (S1/S2/SL) and body.
• Using an ohmmeter, check the resistance between
terminals (STH) and (STHG).

NOTE:
If the pressure contorl solenoid resistance is not within
specification, replace the valve body assembly.
2. Operation Check
Check the solenoid operation by blowing into an oil hole as
shown in the figure.
Solenoid S1 and S2 (Normal close type)
Solenoid S1, S2 and Lock-up
solenoid resistance11 - 15(20C)
12 - 16
(40C)
Pressure control solenoid
resistance5 - 5.6
(20C)
5.4 - 6.1
(40C)
When battery terminal is
disconnectedNo air leaks
When battery terminal is
connectedAir passes through

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–93
DISASSEMBLY OF MAJOR COMPONENTS (2)
242RY00005
Disassembly steps
1. Converter housing
2. Oil pan
3. Oil strainer assembly
4. Solenoid wiring
5. Valve body
6. Check valve, spring
7. Spring
8. Accumulator piston (B-2)
9. Accumulator piston (C-2)
10. Accumulator piston (B-0)
11. Accumulator piston (C-0)
12. Second brake drum gasket

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–107
DISASSEMBLY, INSPECTION AND
REASSEMBLY OF MINOR COMPONENTS
The instructions here are organized so that you work on only
one component group at a time.
This will help avoid confusion from similar-looking parts of
different subassemblies being on your workbench at the same
time.
The component groups are inspected and repaired from the
converter housing side.
As much as possible, complete the inspection, repair and
reassembly before proceeding to the next component group. If
a component group cannot be reassembled because parts are
being ordered, be sure to keep all parts of that group in a
separate container while proceeding with disassembly,
inspection, repair and reassembly of other component groups.
Recommended ATF type BESCO ATF II or III.
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean and any
fluid passages and holes blown through with compressed
air.
2. When using compressed air to dry parts, always aim away
from yourself to prevent accidentally spraying automatic
transmission fluid in your face.
3. The recommended automatic transmission fluid should be
used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the par ts should be arranged in proper order
to allow performing inspection, repairs, and reassembly
with efficiency.
2. When disassembling a valve body, be sure to keep each
valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid for at
least thir ty before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts,
and sliding surfaces should be coated with transmission
fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that ends of a snap ring are not aligned with one
of the cutouts and are installed in the groove correctly.
4. If a worn bushing is to be replaced, the subassembly
containing that bushing must be replaced.
5.Check thrust bearings and races for wear or damage.
Replace if necessary.
6. Use petroleum jelly or vaseline to keep par ts in place.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–109
241RY00006
241RY00007
241RY00008
3. Stator shaft
Remove 13 bolts, and then remove the stator shaft from oil
pump body.
Then remove drive and driven gear.
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
Check oil pump body bushing
Using a dial indicator, measure the inside diameter of the
oil pump body bushing.
If the inside diameter is greater than the maximum, replace
the oil pump body.
Check stator shaft bushing
Using a dial indicator, measure the inside diameter of the stator
shaft bushing.
If the inside diameter is greater than maximum, replace the
stator shaft.mm (in.)
Maximum inside diameter 38.19 (1.5035)
mm (in.)
Maximum inside
diameterFront side 21.58 (0.8496)
Rear side 27.08 (1.0661)

7A–110 AUTOMATIC TRANSMISSION (AW30-40LE)
241RY00009
241RY00010
241RY00011
241RY00012
Check tip clearance of both gears
Measure between the gear teeth and the cresent-shaped
par t of the pump body.
If the tip clearance is greater than the maximum, replace
the drive gear, driven gear or pump body.
Check body clearance of driven gear
Push the driven gear to one side of the body.
Use a feeler gauge, measure the clearance.
If the body clearance is greater than the maximum, replace
the drive gear, driven gear or pump body.
Check side clearance of both gears
Using a steel straightedge and a feeler gauge, measure the
side clearance of both gears.
If the side clearance is greater than the maximum, replace
the drive gear, driven gear or pump body.
Check oil seal
Check for wear, damage or cracks.
If necessary, replace oil seal.
Pry off the oil seal with a screwdriver.mm (in.)
Standard tip clearance0.11–0.14
(0.0043–0.0055)
Maximum tip clearance 0.3 (0.012)
mm (in.)
Standard body clearance0.07–0.15
(0.0028–0.0059)
Maximum body clearance 0.3 (0.012)
mm (in.)
Standard side clearance0.02–0.05
(0.0008–0.0020)
Maximum side clearance 0.1 (0.004)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–113
241RY00006
241RY00015
241RY00016
241RY00017
3. Stator shaft
Align the stator shaft with the bolt holes.
Tighten the thir teen bolts.
4. Oil seal ring
Coat the oil seal rings with ATF.
Contract the oil seal rings as shown, and install them onto
the stator shaft.
NOTE:
Do not spread the ring ends too much.
5. O-ring
Coat a new O-ring with ATF and install it to the oil pump
body.
Check oil pump drive gear rotation
Make sure the drive gear rotates smoothly when installed to
the torque converter.Nꞏm (kgꞏm/Ib in)
Torque 11 (1.1/95)
O-ring size (Reference) mm (in.)
Inside diameter 204.9 (8.067)
Thickness 3.5 (0.138)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–115
252L100003
252L100004
252L100005
252L100016
Important operations
Check operation of one-way clutch
Hold the OD direct clutch drum and turn the input shaft.
The input shaft should turn freely clockwise and should lock
counterclockwise.
(1): Free
(2): Lock
1. OD direct clutch assembly
Remove OD direct clutch assembly from OD planetary
gear.
2. Thrust bearing
Then remove thrust bearing with the race from OD direct
clutch drum.
Check piston stroke of OD direct clutch (C-O)
Place the oil pump onto the torque conver ter, and then
place the OD direct clutch assembly onto the oil pump.
Use a dial indicator, measure the OD direct clutch piston
stroke applying and releasing the compressed air (4– 8 kg/
cm
2, 57– 114 psi, 392– 785 kPa) as shown.
mm (in.)
Piston stroke1.85– 2.15
(0.0728– 0.0847)

7A–124 AUTOMATIC TRANSMISSION (AW30-40LE)
252L100014
252L100005
252L100016
14. Snap ring
Install snap ring.
Check piston stroke of OD direct clutch (C-0).
Place the oil pump onto the torque converter, and then
place the OD direct clutch assembly onto the oil pump.
Using a dial indicator, measure the OD direct clutch piston
stroke by applying and releasing the compressed air (4– 8
kg/cm
2, 57– 114 psi or 392– 785 kPa) as shown.
If the piston stroke is not within specification, replace the
disc and recheck the piston stroke.
If the piston stroke is non standard, select another flange.
There are six flange sizes.mm (in.)
Piston stroke mm (in.)1.85– 2.15
(0.0728– 0.0847)
mm (in.)
No. Flange thickness No. Flange thickness
16 3.6 (0.142) 19 3.3 (0.130)
17 3.5 (0.138) 20 3.2 (0.126)
18 3.4 (0.134) 21 3.1 (0.122)