sensor OPEL FRONTERA 1998 Workshop Manual

7A–1 AUTOMATIC TRANSMISSION (4L30–E)
TRANSMISSION
AUTOMATIC TRANSMISSION (4L30–E)
CONTENTS
Service Precaution 7A–3. . . . . . . . . . . . . . . . . . . . . .
Construction 7A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range Reference Chart 7A–4. . . . . . . . . . . . . . . . . .
Normal Operation Of 2000 4L30–E
Transmission 7A–5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 7A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Information 7A–5. . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis Procedure 7A–8. . . . . . . . . . . . .
Preliminary Inspection Chart 7A–9. . . . . . . . . . . . . .
Checking Transmission Fluid Level and
Condition 7A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Driving 7A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis Check Trans
Indicator Chart 7A–12. . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis
Symptoms Index 7A–13. . . . . . . . . . . . . . . . . . . . . . . .
Stall Test 7A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Test 7A–23. . . . . . . . . . . . . . . . . . . . . .
Shift Speed Chart (V6 3.2L 6VD1 Model) 7A–24. . .
Shift Speed Chart (V6 3.5L 6VE1 Model) 7A–26. .
Lockup Speed Chart (V6 3.2L 6VD1 Model) 7A–28
Lockup Speed Chart (V6 3.5L 6VE1 Model) 7A–28
Changing Transmission Fluid 7A–29. . . . . . . . . . . . .
Selector Lever 7A–29. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 7A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch 7A–31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (With Transfer Case) 7A–33. . . . . . . .
Transmission And Associated Parts 7A–33. . . . . .
Removal 7A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Main Case Valve Body) 7A–39. . . . . . . . .
Removal 7A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Adapter Case Valve Body) 7A–40. . . . . . .
Removal 7A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Main Case) 7A–41. . . . . . . .
Removal 7A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Adapter Case) 7A–43. . . . . .
Removal 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) 7A–43. . . . . . . . .
Removal 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensor (Extension Housing) 7A–44. . . . . . . .
Removal 7A–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–44. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Temperature Sensor
(Adapter Case) 7A–44. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Oil Seal (Converter Housing) 7A–45. . . . . . . .
Removal 7A–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal (Extension Housing) 7A–46. . . . . . . . .
Removal 7A–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (4L30–E) 7A–46. . . . . . . . . . . . . . . . . .
Disassembly 7A–46. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 7A–50. . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Housing And Oil Pump Assembly 7A–60
Disassembled View 7A–60. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–60. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–60. . . . . . . . . . . . . . . . . .
Reassembly 7A–60. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 7A–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7A–61. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–61. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–61. . . . . . . . . . . . . . . . . .
Reassembly 7A–61. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Case Valve Body 7A–62. . . . . . . . . . . . . . . . . . .
Disassembled View 7A–62. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–62. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–63. . . . . . . . . . . . . . . . . .
Reassembly 7A–63. . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter Case Valve Body 7A–64. . . . . . . . . . . . . . . .
Disassembled View 7A–64. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–64. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–64. . . . . . . . . . . . . . . . . .
Reassembly 7A–64. . . . . . . . . . . . . . . . . . . . . . . . . .
Third Clutch And Sprag Unit 7A–65. . . . . . . . . . . . . .
Disassembled View 7A–65. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–65. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–66. . . . . . . . . . . . . . . . . .

7A–18
AUTOMATIC TRANSMISSION (4L30–E)
Chart 9c: Coastdown Harsh Shift Or Clunk At 3–2 Downshift
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
2Does DTC P1850 set?
Diagnose P1850
first
Replace band
apply solenoid
(PWM) (323)
Chart 10: Intermittent 4TH TO 2ND Gear Downshift At Steady Speed
StepActionYe sNo
1Check for consistent speed sensor reading with scan tool.
Was the reading correct?Replace mode
switch for
intermittent
contact.
Go to Step 2
21. Check for wiring harness damage or short to ground. If OK, go
to (2).
2. Check transmission speed sensor connections. If OK, go to
(3).
3. Replace transmission speed sensor.
Was the replacement complete?
—
Replace speed
sensor.
Chart 11: Engine Flare At Shifting During Turning Only (Usually With Warm Engine)
StepActionYe sNo
1Check for oil leaks at transmission.
Was the problem found?Replace
transmission oil
filter and gasket
—
Chart 12: Engine Flare During 1–2 Or 2–3 Shift
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
21. Check for a stuck 1–2 accumulator valve (320).
2. Check for servo piston (106) leaks.
3. Check for a stuck band apply solenoid (323).
Was line pressure normal?
Repair or replace—

7A–20
AUTOMATIC TRANSMISSION (4L30–E)
Chart 15a: Possible Causes of Low Line Pressure
StepActionYe sNo
1Check oil level.
Was the problem found?
Fill with ATFGo to Step 2
2Check for defective throttle position sensor.
Was the problem found?Replace throttle
position sensor
Go to Step 3
3Check for plugged, loose, or damaged oil filter (79).
Was the problem found?Inspect oil filter,
tighten bolts or
replace oil filter
(79)
Go to Step 4
4Check for a stuck force motor plunger (404). (Adapter case valve
body)
Was the problem found?Replace force
motor plunger
(404)
Go to Step 5
5Check for a stuck feed limit valve (412). (Adapter case valve body)
Was the problem found?Replace feed limit
valve (412)
Go to Step 6
6Check for loose converter bolts (4 & 5).
Was the problem found?Tighten converter
bolts (4 & 5)
Go to Step 7
7Check for a stuck pressure regulator valve (208). (Oil pump)
Was the problem found?Replace pressure
regulator valve
(208)
Go to Step 8
8Check for a stuck boost valve (205).(Oil pump)
Was the problem found?Replace boost
valve (205)
Go to Step 9
9Check for blocked intermediate oil passages to pressure
regulator valve. (Oil pump)
Was the problem found?
Replace oil pumpGo to Step 10
10Check for defective oil pump (9, 201, 202 & 209).
Was the problem found?
Replace oil pumpGo to Step 11
11Check for internal leaks.
– Check balls missing or out of location in valve bodies
– Seals cut or damaged
– Gaskets defective, etc.
Was the problem found?Install balls, or
correct ball
location
Replace seals
Replace gaskets
—

7A–21 AUTOMATIC TRANSMISSION (4L30–E)
Chart 15b: Possible Causes Of High Line Pressure
NOTE: If transmission is operating in backup mode, high
line pressure will be present.
Step
ActionYe sNo
1Check for defective throttle position sensor.
Was the problem found?Replace throttle
position sensor.
Go to Step 2.
2Check for a stuck force motor plunger (404). (Open
circuit/intermittent) (Adapter case valve body)
Was the problem found?Replace force
motor plunger
(404)
Go to Step 3
3Check for a stuck feed limit valve (412). (Adapter case valve body)
Was the problem found?Replace force
motor plunger
(412)
Go to Step 4
4Check converter bolts (4 & 5).
Was the problem found?Tighten converter
bolts (4 & 5)
Go to Step 5
5Check for a stuck pressure regulator valve (208). (Oil pump)
Was the problem found?Replace pressure
regulator valve
(208)
Go to Step 6
6Check for a stuck boost valve (205). (Oil pump)
Was the problem found?Replace boost
valve (205)
Go to Step 7
7Check for internal leaks.
– Check balls missing or out of location in valve bodies
– Seals cut or missing
– Gaskets defective, etc.
Was the problem found?Install balls, or
correct ball
location
Replace seals
Replace gaskets
—

7A–22
AUTOMATIC TRANSMISSION (4L30–E)
Chart 16: Possible Causes Of
Transmission Fluid Leaks
Before attempting to correct an oil leak, the actual source
of the leak must be determined. In many cases, the
source of the leak may be difficult to determine due to
“wind flow” around the engine and transmission.
The suspected area should be wiped clean before in-
specting for the source of the leak.Oil leaks around the engine and transmission are gener-
ally carried toward the rear of the vehicle by the air
stream. In determining the source of an leak, the following
two checks should be made:
1. With the engine running, check for external line
pressure leaks.
2. With the engine off, check for oil leaks due to the
raised oil level caused by drainback of converter oil
into the transmission.
Possible Causes Of Fluid Leaks Due To Sealing Malfunction
240RX008
Legend
(1) Electrical Connector (Main Case) Seal
(2) Transmission Vent (Breather)
(3) Speed Sensor O–Ring
(4) Extension (Adapter) Lip Seal
(5) Extension (Adapter) to Main Case Gasket
(6) Overfill and Oil Drain Screws Gasket
(7) Oil Pan Gasket (Main Case)
(8) Selector Shaft Seal(9) Oil Cooler Connectors (2)
(10) Oil Pan Gasket (Adapter Case)
(11) Converter housing attaching bolts not correctly
torqued
(12) Converter Housing Lip Seal
(13) Line Pressure Tap Plug
(14) Electrical Connector (Adapter Case) Seal
(15) Adapter Case Seal Rings (2)

7A–34
AUTOMATIC TRANSMISSION (4L30–E)
4. Disconnect shift lock cable from the selector lever
assembly side.
256RW012
5. Disconnect wiring harness connectors.
6. Disconnect shift control rod from the selector lever
assembly side.
256RW013
7. Remove selector lever assembly (3).
8. Remove transfer control lever (4).
9. Remove transfer and exhaust protector (5).
10. Remove rear propeller shaft (6).
11. Remove front propeller shaft (7).
12. Remove harness protector (8).
13. Support transfer case with a jack and remove two rear
mount nuts (9) from the 3rd crossmember side.
14. Remove eight third crossmember bolts and third
crossmember (10).15. Disconnect one oxygen sensor connector from the
transmission harness.
150RW002
16. Remove exhaust pipe (11).
17. Disconnect transmission oil cooler pipe (12) from A/T
side.
18. Remove oil pipe clamp from torque converter
housing bracket.
253RY001
19. Loosen oil pipe clamp bolt at the engine mount side.
20. Remove starter (13).
21. Disconnect fuel pipe clamp bracket from
transmission side.
22. Disconnect transmission harness connectors (14)
from transmission, and transfer.
23. Remove under covers (3 pieces) (15) from
transmission case.
24. Lower the front of the transmission a little, then
remove flex plate torque converter fixing bolts (6
pieces) (16) by turning crankshaft.
25. Support the transmission with a transmission jack,
and hoist engine with a chain block.
26. Remove engine transmission fixing bolts (17).

7A–37 AUTOMATIC TRANSMISSION (4L30–E)
For 44 (TOD)
141RW001
9. Install transmission oil cooler pipe to transmission.
Torque: 44 N
m (4.5 kgꞏm/33 lb ft)
10. Install oil pipe clamp to torque converter housing
bracket.
11. Tighten oil pipe clamp bolt at engine mount side.
12. Install exhaust pipe, and tighten the bolts to the
specified torque.
Exh. pipe to exh. manifold 67 N
m
(6.8 kgꞏm/49 lb ft)
Exh. pipe flange bolt 43 N
m (4.4 kgꞏm/32 lb ft)
13. Connect one oxygen sensor connector to the
transmission harness.14. Install third crossmember, and tighten the bolts to the
specified torque.
To r q u e : 7 6 N
m (7.8 kgꞏm/56 lb ft)
15. Install rear mount nuts, and tighten the nuts to the
specified torque.
To r q u e : 5 0 N
m (5.1 kgꞏm/37 lb ft)
16. Remove the jack from the transfer case.

7A–39 AUTOMATIC TRANSMISSION (4L30–E)
Solenoid (Main Case Valve Body)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Remove transfer and exhaust protectors.
4. Drain fluid.
5. Remove exhaust pipe and disconnect oxygen sensor
connector.
6. Support transfer case with a jack and remove third
crossmember.
7. Remove sixteen 10 mm screws, main case oil pan,
magnet, and gasket.
8. Remove three 13 mm screws, oil filter.
9. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
10. Remove spring pin for shift solenoid A, shift solenoid
B, and band control solenoid respectively, using
suitable pliers taking care not to damage solenoids.
210RW010
244RW003
11. Remove shift solenoid A, shift solenoid B, band
control solenoid, and gaskets from main case valve
body. Do not pull on wiring harness. Remove
solenoids by grasping the metal tip.
Installation
1. Install shift solenoid A, shift solenoid B, band control
solenoid with new gaskets to main case valve body
respectively.
2. Carefully install spring pin with hammer to avoid
damage to valve body, etc.
243RW004
3. Connect wiring harness to solenoids.
4. Install oil filter with a new gasket and the three 13 mm
screws. Tighten the screws to the specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
5. Install magnet, main case oil pan with new gasket,
sixteen 10 mm screws. Tighten the screws to the
specified torque.
To r q u e : 11 N
m (1.1 kgꞏm/96 lb in)
6. Install third crossmember and rear mount nuts.
Tighten the nuts and bolts to the specified torque.
Third crossmember bolt: 76 N
m
(7.8 kgꞏm/56 lb ft)
Rear mount nut: 50 N
m (5.1 kgꞏm/37 lb ft)
7. Install exhaust pipe and connect oxygen sensor
connector. Tighten the bolts to the specified torque.
Exhaust pipe flange bolt torque:
43 N
m(4.4kgꞏm/32lbft)
8. Install the transfer and exhaust protectors. Tighten
the bolts to the specified torque.
Torque: 37 N
m (3.8 kgꞏm/27 lb ft)
9. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
10. Connect the battery ground cable.

7A–40
AUTOMATIC TRANSMISSION (4L30–E)
Solenoid (Adapter Case Valve Body)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Drain fluid.
4. Remove transfer and exhaust protectors.
5. Remove exhaust pipe and disconnect oxygen sesnor
connector.
6. Remove adapter case oil pan twelve fixing 10 mm
screws, adapter case oil pan, and gasket.
NOTE: Oil pan still contains transmission fluid. Place a
large drain container under the oil pan and drain the fluid
carefully.
7. Disconnect wiring harness from force motor solenoid
and converter clutch solenoid. Pull only on
connectors, not on wiring harness.
8. Remove 11 mm bolt and converter clutch solenoid
with two O–rings.
210RW011
9. Remove 11 mm bolt, retainer, and force motor
solenoid.
210RW009
Installation
1. Install force motor solenoid, retainer, and 11 mm bolt
to adapter case valve body. Tighten the bolt to the
specified torque.
To r q u e : 1 0 N
m (1.0 kgꞏm/87 lb in)
2. Install converter clutch solenoid with two O– rings,
and 11 mm bolt to adapter case valve body. Tighten
the bolt to the specified torque.
Torque : 10 N
m (1.0 kgꞏm/87 lb in)
3. Connect wiring harness assembly to solenoids.
4. Install adapter case oil pan, new gasket, and twelve
10 mm screws. Tighten the screws to the specified
torque.
Torque : 11 N
m (1.1 kgꞏm/96 lb in)
5. Install exhaust pipe and connect oxygen sensor
connector. Tighten the bolt to the specified torque.
Exhaust pipe flange bolt torque :
43 N
m(4.4kgꞏm/32lbft)
6. Install transfer and exhaust protectors. Tighten the
bolt to the specified torque.
Torque : 37 N
m(3.8kgꞏm/27lbft)
7. Fill transmission through overfill screw hole oil pan,
using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
8. Connect battery ground cable.

7A–41 AUTOMATIC TRANSMISSION (4L30–E)
Valve Body Assembly (Main Case)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Remove transfer and exhaust protectors.
4. Drain fluid.
5. Remove exhaust pipe and disconnect oxygen sensor
connector.
6. Support transfer case with a jack and remove third
crossmember.
7. Remove sixteen 10 mm screws, main case oil pan,
magnet and gasket.
8. Remove three 13 mm oil filter fixing screws, then
remove oil filter.
9. Remove two 13 mm manual detent fixing screws,
then remove roller and spring assembly.
10. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
11. Remove four 13 mm servo cover fixing screws, then
remove servo cover and gasket.
12. Remove seven 13 mm valve body fixing screws.
Disconnect the ground wire from the main case
valve body.
13. Remove main case valve body with manual valve link
and transfer plate. Note the position of the link (long
end into valve, short end into range selector lever).
14. Remove transfer plate gasket from main case.
15. Remove two check balls from main case.
Installation
1. Install two check balls to main case.
244RW002
2. Inspect electrical 4 pin connector and seal of main
case. Replace if necessary.3. Use two 5–8840–0022–0 (J–25025–B) guide pin to
install main case.
Install valve body assembly and manual valve link.
NOTE: Valve must be extended as the short end of
manual valve link is connected to the range selector lever.
Long end of link goes into valve.
4. Install seven 13 mm screws, and tighten them to the
specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
243RS008
5. Install 8.5 mm connector of ground wire the head of
this valve body bolt and reinstall it. Tighten the bolt to
the specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
244RW001
6. Remove two guide pins from main case.
7. Install servo cover gasket, cover, and four 13 mm
screws. Tighten the screws to the specified torque.
To r q u e : 2 5 N
m (2.6 kgꞏm/18 lb ft)