air condition OPEL FRONTERA 1998 Workshop Manual

7A–11 AUTOMATIC TRANSMISSION (4L30–E)
Fluid Condition
FLUID CONDITION
NORMAL*CONTAMINATED
COLORRED OR LIGHT
BROWNBROWNNON–TRANSPARENT
/ PINKBROWN
DRAIN
REQUIRED?NOYESYESYES
CONTAMINA–
TIONNONEVery small amount of
foreign material in
bottom of panContamination by
coolant or other sourceLarge pieces of metal
or other foreign
material in bottom of
pan
CORRECT
LEVEL AND
CONDITION
1. LOW LEVEL:
A. Add fluid to
obtain proper
level & check for
external leaks.
B. Correct cause of
leak.
2. HIGH LEVEL:
– Remove excess
fluid– Remove both pans
– Change filter
– Flush cooler
– Add new fluid
– Check level– Repair/replace
radiator cooler
–Transmission
overhaul required
– Check for:
Damaged plates
and seals
Contaminated
solenoids
– Flush cooler
– Add new fluid
– Check level
–Transmission
overhaul required
– Flush cooler and
cooler lines
– Add new fluid
– Check level
*Fluid should be changed according to maintenance
schedule.
Te s t D r i v i n g
Some 4L30–E automatic transmission complaints will
require a test drive as a part of the diagnostic procedure.
Some codes will not set unless the vehicle is moving. The
purpose of the test drive is to duplicate the customer’s
complaint condition and set a current Powertrain Control
Module (PCM) trouble code. Perform this procedure
before each 4L30–E automatic transmission repair, and
again after repairs are made.
IMPORTANT:
Duplicate the condition under which the customer’s
complaint was observed.
Depending on the complaint, the line pressure gauge
and the scan tool may be required during the test
drive.
During the test drive, it is important to record all
necessary data from the areas being monitored, for
use in diagnosis. Also listen for and note any unusual
noises.
The following procedure should be used to test drive
4L30–E automatic transmission complaint vehicles:
1. Turn the ignition ON without starting the engine.
Check that the “CHECK TRANS” lamp comes on for
approximately 2 seconds and then goes out and
remains out.
If the lamp is flashing, GOTO Check Trans Indicator
in Transmission Control System (4L30–E) section.
If no serial data is present, GOTO OBD System
Check. Refer to Driveability and Emissions in
Engine section.
If the lamp stays ON or stays OFF, GOTO “Check
Trans” Check in Transmission Control System
(4L30–E) section.
2. Drive the vehicle. During the test drive, be sure that
the transmission achieves normal operating
temperature (approx. 20 minutes).
Allow the transmission to go through all of its gear
ranges, checking shift timing and firmness. Duplicate
the owner’s complaint condition as closely as
possible during the test drive.
3. If, during the test drive, the “CHECK TRANS” lamp
comes on, use the scan tool to check for trouble
codes.
4. If, during the test drive, a problem is felt, but the
“CHECK TRANS” lamp does not come on and no
trouble codes are present, drive the vehicle with the
PCM disconnected (manually shifting the vehicle).
In Manual L, the vehicle operates in first gear.
In Manual 2, the vehicle operates in third gear.
In Manual 3 or “D”, the vehicle operates in fourth
gear.
If the problem still exists with the PCM disconnected,
refer to Mechanical/Hydraulic Diagnosis in this
section.
5. If no problem has been found at this point, check all
underhood connections that supply power to the PCM
and ignition fuses. Physically and visually inspect all
the PCM harness connectors for loose or corroded
terminals. Inspect the PCM ground points.

7A–13 AUTOMATIC TRANSMISSION (4L30–E)
Mechanical / Hydraulic Diagnosis Symptoms Index
Perform Preliminary Inspection First!
CHART
SYMPTOMS
1NO ENGINE START IN NEUTRAL OR PARK
2NO FORWARD GEARS IN ANY RANGE/NO REVERSE
3NO ENGINE BRAKE IN ANY RANGE
4POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT)
5aDELAYS IN DRIVE AND REVERSE
5bDELAYS IN REVERSE ONLY
6DIAGNOSTIC TROUBLE CODE (DTC) P0730
7HARSH 1–2 SHIFT
8HARSH 3–4 SHIFT
9a3–2 DOWNSHIFT COMPLAINT
9bHARSH SHIFT WHEN SHIFTING INTO “D” OR ACCELERATING FROM STOP
9cCOASTDOWN HARSH SHIFT OR CLUNK AT 3–2 DOWNSHIFT
10INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED
11ENGINE FLARE AT SHIFTING DURING TURNING ONLY (USUALLY WITH WARM ENGINE)
12ENGINE FLARE DURING 1–2 OR 2–3 SHIFT
13SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING
14POSSIBLE CAUSES OF TRANSMISSION NOISE
15aPOSSIBLE CAUSES OF LOW LINE PRESSURE
15bPOSSIBLE CAUSES OF HIGH LINE PRESSURE
16POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS
NOTE: Numbers with parenthesis on the following charts
refer to Parts List at end of this section.
Chart 1: No Engine Start In Neutral Or Park
StepActionYe sNo
1Does engine start when shift lever moved from drive to neutral
mostly in hot condition?
Go to Step 2Go to Step 3
2Does engine start in park at any condition?Re–test vehicleGo to Step 4
3Does engine also not start in neutral when shift lever moved from
park to neutral?
Go to Step 4Go to Step 5
4Check mode switch (63) setting. Readjust if necessary.
Problems fixed?
Re–test vehicleGo to Step 5
5Check start circuit of mode switch (63) open in neutral.
Was open found?Locate and repair
open(s)Replace mode
switch (63)

7A–15 AUTOMATIC TRANSMISSION (4L30–E)
Chart 4: Poor Shifting In All Gears (All Harsh Or All Soft)
StepActionYe sNo
1Check line pressure. Refer to Line Pressure Test in this section.
Was line pressure normal?
Go to Step 2Go to Step 3
21. Check for these conditions which could affect clutch apply
time:
– Defective band apply solenoid (323).
– Defective servo or/and accumulator piston.
– Excessive clutch piston travel.
2. Check of possible causes of internal leaks:
– Cut or damaged sealing ring(s)
– Damaged sealing gasket(s)
– Check ball missing or out of location in 2nd and 3rd clutch
pistons.
3. Check for caused of burned clutch plates or band.
Was the problem found?
Repair or replace—
3Was the line pressure high?
Go to Step 4
Use Chart 15a:
Possible Causes
of Low Line
Pressure in this
section
4Were DTCs P0560 and P0705 set?
Diagnose those
DTC(s) first
Use Chart 15b:
Possible Causes
of High Line
Pressure in this
section
Chart 5a: Delays In Drive And Reverse
NOTE: A short delay (less than 3 seconds) when first
engaging drive or reverse after allowing vehicle to sit
overnight is normal.
Step
ActionYe sNo
1Check line pressure. Refer to Line Pressure Test in this section.
Was line pressure normal?More than 3
second delay in
drive and reverse
with engine off 1
hour or less.
Teflon seals (508)
on turbine shaft
damaged. Repair
Use Chart 15a:
Possible Causes
of Low Line
Pressure in this
section.
Chart 5b: Delays In Reverse Only
StepActionYe sNo
1Check line pressure. Refer to Line Pressure Test in this section.
Was line pressure normal?
Go to Step 2
Use Chart 15a:
Possible Causes
of Low Line
Pressure in this
section.
2Main case valve body gasket (88) damaged.
– Reverse check ball (85) in valve body (84) missing or out of
location.
– Check for restrictions at valve body transfer plate orifice.
Was the problem found?
Repair—

7A–16
AUTOMATIC TRANSMISSION (4L30–E)
Chart 6: Diagnostic Trouble Code (DTC) P0730
StepActionYe sNo
1Check line pressure. Refer to Line Pressure Test in this section.
Was line pressure normal?
Go to Step 2
Use Chart 15b:
Possible Causes
of High Line
Pressure in this
section
21. 1st and 2nd gear missing or 3rd and 4th gear missing.
Check appropriate shift valve. If OK replace solenoid.
2. No engine brake in any range (All ranges in Drive and Reverse
are OK).
Check for suspected conditions modifying delays to clutch
apply:
– Overrun clutch seal damaged.
– Excessive overrun clutch piston travel.
– Defective 3–4 accumulator piston.
– Causes of internal leaks.
– Causes of burned clutch plates.
3. 1st and 4th gear missing or 2nd and 3rd gear missing.
Shift solenoid A stuck. Replace shift solenoid A.
4. DTC P0730 is set in D range 1st gear above 3500 rpm.
Go to Step 3.
5. DTC P0730 is set in D range 3rd gear between 55-80 mph.
NOTE: Perform this test within safe and legal limits.
Check for suspected conditions modifying delays to clutch
apply:
– 4th clutch seal damaged.
– Excessive 4th clutch piston travel.
– Defective 3–4 accumulator piston.
– Causes of internal leaks.
– Causes of burned clutch plates.
Was the problem found?
Repair or replace—
3Check 3rd gear in “D” in winter mode.
Does vehicle move?Shift solenoid A
stuck. Replace
shift solenoid A.
Go to Step 4
4Check for suspected conditions modifying delays to clutch apply:
– 2nd clutch seal damaged.
– Excessive 2nd clutch piston travel.
– Defective accumulator piston.
– Causes of internal leaks.
– Check ball missing or out of location in 2nd clutch.
– Seals cut, damaged or missing.
– Gaskets defective.
– Causes of burned clutch plates.
Was the problem found?
Repair or replace—

7A–19 AUTOMATIC TRANSMISSION (4L30–E)
Chart 13: Shudder Only During Torque Converter Clutch (TCC) Applying
StepActionYe sNo
11. TCC shudder is one of the most commonly misdiagnosed
conditions in an automatic transmission. The key to
diagnosing TCC shudder is to note when it happens and under
what conditions. Once the TCC has been fully applied, it is
nearly impossible to make it shudder. TCC shudder (short
burst of noise normally less than 1 second) will only occur
during clutch applying. It is not a steady state condition.
2. Drive until whole drivetrain is at normal operating temperature.
– On 4WD vehicles, the test must be performed with transfer
case selector lever in “2H” position.
– Shudder is a short burst of noise normally less than 1 second
in duration, and can be induced by the following maneuver:
3. From coast condition at 50 mph in “D” range (Normal mode),
depress the throttle to 1/4-1/3 throttle. If present, shudder will
occur within 5 seconds together with TCC application.(The
scan tool may be used to determine the exact time of TCC
applying)
Was the problem found?
Replace
transmission fluid
and filter (remove
both pans) and
flush cooler lines.
Replace
converter
assembly and
O-ring on turbine
shaft
Perform
mechanical
inspection of
other drivetrain
components.
Chart 14: Possible Causes Of Transmission Noise
CAUTION: Before checking transmission for what
is believed to be transmission noise, ensure
presence and positioning of insulating plugs, pads
etc. Also make sure that noise does not come from
other drivetrain components.
Condition
Possible causeCorrection
Whine or BuzzOil level lowFill with ATF, check for external
leaks.
Plugged or restricted oil filterInspect oil filter.
Replace oil filter or ATF as necessary.
Damaged oil filter gasketReplace oil filter gasket.
Knocking noise from front of
transmission
Loose bolts (Converter to flex plate)Tighten to specifications.
transmission.Cracked or broken flex plateReplace flex plate.
Converter damagedReplace converter.
Knocking noise while driving, mostly
on acceleration.Transmission mount loose or brokenTighten mount bolts or replace
transmission mount.
Cooler line mounts loose or brokenTighten or replace cooler line
mounts.
Cooler lines touching body or frameRepair or replace as necessary.
Knocking noise when vehicle is
stationary
Loose flex plate mounting boltsTighten to specifications.
stationary.Cracked or broken flex plateReplace flex plate.
Damaged converterReplace converter.

7A–2 AUTOMATIC TRANSMISSION (AW30-40LE)
VALVE BODY ASSEMBLY AND PRESSERE CONTOROL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . 7A–84
TRANSMISSION REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–86
UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–91
DISASSEMBLY OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–91
DISASSEMBLY, INSPECTION AND REASSEMBLY OF MINOR COMPONENTS. . . . . . . . . . . . . . . . . 7A–107
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–108
OD PLANETARY GEAR AND OD DIRECT CLUTCH ASSEMBLY (C-0) . . . . . . . . . . . . . . . . . . . . . . . . 7A–114
OD SUPPORT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–126
DIRECT CLUTCH ASSEMBLY (C-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–133
FORWARD CLUTCH ASSEMBLY (C-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–141
FRONT PLANETARY GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–150
PLANETARY SUN GEAR AND NO.1 ONE–WAY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–153
SECOND BRAKE ASSEMBLY (B–2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–158
REAR PLANETARY GEAR ASSEMBLY AND OUTPUT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–163
FIRST AND REVERSE BRAKE (B–3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–171
TRANSMISSION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–177
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–181
REASSEMBLY OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–182
MAIN DATA AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–207
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–207
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–208
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–211
CAUTION: When fasteners are removed, always
reinstall them at a the same location from which
they were removed. If a fastener needs to be
replaced, use the correct part number fastener for
that application. If the correct part number fastener
is not available, a fastener of equal size and
strength (or stronger) may be used. Fasteners that
are not reused, and those requiring thread locking
compound, will be called out. The correct torque
values must be used when installing fasteners that
require torque. If the above conditions are not
followed, parts or system damage could result.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–17
DIAGNOSIS WITH TECH2
In this AW30-40LE transmission, troubleshooting can be
performed for electrical faults using the Tech2 scan tool.
If the CHECK TRANS lamp blinks, or if an electrical fault in the
transmission may probably exist, check trouble codes using the
Tech2 scan tool.
In the diagnostic procedures described in this manual, first
repair the faulty positions indicated by trouble code in the order
of numbers and then perform troubleshooting for the faulty
positions that are not indicated by trouble code. For correct
troubleshooting, it is necessary to first repair the trouble codes
of lower-order numbers, then to repair the trouble codes of
higher-order numbers in sequence.
How to Use This Manual:
Check trouble codes using the Tech2 scan tool.
If no codes are set:
•Refer to
F1: Data Display and identify the electrical faults
that are not indicated by trouble code.
If codes are set:
• Record all the codes displayed by the Tech2 and check if the
codes are intermittent (intermittent faults).
• Clear the codes.
• Drive the vehicle for a test to reproduce the faulty status.
• Check trouble codes again using the Tech2.
• If no code is displayed by test driving, the fault is intermittent.
In this case, refer to the cautions on intermittent conditions.
• If a code is present, refer to "DIAGNOSTIC TROUBLE
CODES (DTC) CHECK" for diagnosis.
• Because a code of high-order number may be set for the
reason that a code of low-order number has been set after
occurrence of a fault, perform repair work starting with a
lower-order number is ascending order.

7A–20 AUTOMATIC TRANSMISSION (AW30-40LE)
Once the test vehicle has been identified an “Application
(Power train) Menu" screen appears. Please select the
appropriate application.
The following table shows, which functions are used for
the available equipment versions.
Diagnostic Trouble Codes
The purpose of the “Diagnostic Trouble Codes" mode is
to display stored TCM trouble codes.
When “Diagnostic Trouble Codes" is selected an
“Application Menu" screen appears.
Clear DTC Information
The purpose of the “Clear DTC Information" mode is to
command the clearing of stored TCM trouble codes.
When “Clear DTC Information" is selected, a “Clear
DTC Information", warning screen appears. This screen
informs you that by cleaning DTC's, “all stored DTC
information in controller will be erased".
Do you want to clear DTC's (Yes/No).
Press either the Yes or No key when answering.
After clearing codes, confirm system operation by test
driving the vehicle.
Allow the vehicle to shift through all four forward gears in
a manner which attempts to repeat the failure condition.
NOTE: When the trouble has not been repaired and thetrouble code cannot be erased, check the vehicle again.
DTC Information
When “DTC Information" is selected, an “Application
Menu" appears with a list of DTC information function
keys addressing DTC specifics and their origins.
Function key selections may vary for particular vehicle
and/or system.
Data Display
The purpose of the “Data Display" mode is to
continuously monitor data parameters.
The current actual values of all impor tant sensors and
signals in the system are display through F1 mode.
When “Data Display" is selected an “Application Menu"
appears.
See “TRANSMISSION DATA" and “TCC DATA” on next
page.
Snapshot
When “Snapshot" is selected an “Application Menu"
appears.
When “Transmission Snapshot" application is selected
from the “Application Menu", a “Snapshot Menu"
appears, displaying several options. “Snapshot" options
may vary from one system to another.
“Snapshot" allows a recording of all vehicle parameters.
There parameters may then be replayed at a future
point in time.
This action allows you to focus on making the condition
occur, rather than trying to view all of the data in
anticipation of the fault. The snapshot will collect
parameter information around a trigger point that you
select.
When a snapshot is taken. It is recorded onto the
PCMCIA memory card. When the Tech2 is powered
down. Snapshots are not lost.
Actuator Tests
The purpose of “Actuator Tests" mode is to check for
correct operation of electronic system actuators.
Lamps
You can operate the lamps by pressing the ON and OFF
buttons.
Preconditions: P or N position
Solenoid
Solenoid S1(1-2/3-4), S2(2-3) and TCC Solenoid
(Torque Converter Clutch)
You can operate the solenoids by pressing the ON and
OFF buttons.
Preconditions: P or N position, no vehicle speed, no
engine speed
Pressure Control Solenoid (PCS)
You can operate the PC Solenoid by pressing the ON
and OFF buttons. ON will command a maximum current
of 1000 mA and OFF a minimum of 200 mA.
Preconditions: P or N position, no vehicle speed, engine
running F0: Diagnostic Trouble Codes
F0: Read DTC Info Ordered By Priority
F1: Clear DTC Information
F2: DTC Information
F0: History
F1: MIL SVS or Message Requested
F2: Last Test Failed
F3: Test Failed Since Code Cleared
F4: Not Ran Since Code Cleared
F5: Failed This Ignition
F1: Data Display
F0: Transmission Data
F1: TCC Data
F2: Snapshot
F3: Actuator Tests
F0: Lamps
F0: Check Light Test
F1: Power Lamp Test
F2: Winter Lamp Test
F3: AT Oil Temperature Lamp Test
F1: Solenoids
F0: Solenoid 2-3 Test
F1: Solenoid 1-2/3-4 Test
F2: TCC Solenoid Test
F3: Pressure Control Solenoid (PCS)

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–128 AUTOMATIC TRANSMISSION (AW30-40LE)
252RY00046
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
Check piston return spring
Using calipers, measure the free length of the return spring.
mm (in.)
Standard 17.2 (0.677)