OPEL FRONTERA 1998 Workshop Manual

7A–90 AUTOMATIC TRANSMISSION (AW30-40LE)
Transmission-Transfer Case Bolt Torque
260RY00001

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–91
UNIT REPAIR
DISASSEMBLY OF MAJOR COMPONENTS (1)
240RY00024
NOTE:
Steps marked with a triangle (
) are important
operations. Detailed information appears in the text.
Disassembly steps
1. Torque conver ter
2. Breather hose
3. Transmission ocntrol rod and shift lever
4. Neutral start switch
5. Elbow
6. Oil temperature sensor
7. Input revolution sensor
8. Output revolution sensor
9. Adapter housing
10. Transmission assembly

7A–92 AUTOMATIC TRANSMISSION (AW30-40LE)
249RW003
240RY00001
240RY00002
Important operations
3. Transmission control rod and shift lever
Remove the transmission control rod and shift lever.
4. Neutral start switch
Unstake the lock washer.
Remove the nut and bolts, and then remove the neutral star t
sw itc h.
Remove the lock washer and grommet.
5. Elbow
Remove two elbows from transmission case.
Install special tool to the transmission unit.
Holding fixture: 5-8840-2152-0 (J-37227)
Fixture base: 5-8840-0003-0 (J-3289-20)

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

7A–94 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00006
240RY00007
240RY00008
244RY00003
Important operations
1. Converter housing
Remove the six bolts.
Remove the transmission housing.
2. Oil pan
NOTE:
Do not turn over the transmission as this will contaminate
the valve body with foreign materials in the bottom of the
pan.
Remove the nineteen bolts.
Remove pan by lifting the transmission case.
Seal cutter: 5-8840-2153-0 (J-37228)
Examine particles in pan
Remove the magnet and use it to collect any steel chips.
Look carefully at the chips and par ticles in the pan and on
the magnet to anticipate what type of wear you will find in
the transmission:
Steel (magnetic).....bearing, gear and clutch plate wear
Brass (non-magnetic)...bushing wear
3. Oil strainer assembly
Remove four bolts holding the oil strainer.
NOTE:
When reassembling components, install a new oil strainer
assembly.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–95
249RY00011
249RY00012
244RY00017
240RY00028
4. Solenoid wiring
Disconnect the connectors from the solenoid S1(1), S2(2),
lock-up solenoid (3) and pressure control solenoid (4).
Turn over transmission, remove the solenoid wiring stopper
plate from the case.
Pull the wiring out of the transmission case.
5. Valve body
Remove the twenty bolts from valve body.
6. Check valve, spring
7. Spring
Remove the check valve and spring.
Remove two springs from C-0 accumulator piston.

7A–96 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00010
240RY00011
240RY00012
8. Accumulator piston (B-2)
9. Accumulator piston (C-2)
Remove accumulator pistons and springs from
transmission case.
10. Accumulator piston (B-0)
Applying compressed air to the oil hole, remove the B-0
accumulator piston and spring.
11. Accumulator piston (C-0)
Remove the C-0 accumulator piston.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–97
DISASSEMBLY OF MAJOR COMPONENTS (3)
248L100001
Disassembly steps
1. Oil pump
2. Race
3. OD planetary gear and OD direct clutch
4. Race
5. OD planetary ring gear
6. Snap ring
7. Flange, plate and disc
8. Bearing and race
9. Snap ring
10. OD suppor t
11. Race
12. Snap ring
13. Second coast brake piston assembly
14. Direct clutch and forward clutch
15. E-ring and pin
16. Second coast brake band
17. Front planetary ring gear
18. Bearing and race
19. Race
20. Snap ring
21. Front planetary gear
22. Drum and one-way clutch
23 Snap ring
24. Flange, plate and disc
25. Snap ring
26. Rear planetary gear, second brake drum
and output shaft
27. Bearing

7A–98 AUTOMATIC TRANSMISSION (AW30-40LE)
241RY00003
241RY00002
252L100001
252L100017
Important operations
1. Oil pump
Remove seven bolts fixing the oil pump to the transmission
case.
Remove the oil pump.
2. Race
Remove race from oil pump.
3. OD planetary gear and OD direct clutch
Remove the overdrive planetary gear and overdrive direct
clutch with thrust needle bearing from the transmission
case.
4. Race
Remove the race from OD planetary gear.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–99
252RY00002
252RY00003
244RY00001
246RY00001
5. OD planetary ring gear
Remove the overdrive planetary ring gear from the
transmission case.
Check piston stroke of overdrive brake
Place a dial indicator onto the overdrive brake piston as
shown in the figure.
Measure the stroke applying and releasing the compressed
air (4– 8kg/cm
2, 57– 114 psi or 392– 785kPa) as shown in
the figure.
mm (in.)
If the values are nonstandard, select another flange.
6. Snap ring
Remove the snap ring.Piston stroke1.40–1.70
(0.0551–0.0669)
Available flange sizes mm (in.)
3.3 (0.130) 3.8 (0.150)
3.5 (0.138) 3.9 (0.154)
3.6 (0.142) 4.0 (0.158)
3.7 (0.146)