clutch OPEL FRONTERA 1998 Workshop Manual

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–23 AUTOMATIC TRANSMISSION (4L30–E)
Stall Test
The stall test allows you to check the transmission for
internal abrasion and the one way clutch for slippage.
Torque converter performance can also be evaluated.
The stall test results together with the road test results will
identify transmission components requiring servicing or
adjustment.
Stall Test Procedure:
1. Check the level of the engine coolant, the engine oil,
and the automatic transmission fluid. Replenish if
necessary.
2. Block the wheels and set the parking brake.
3. Connect a tachometer to the engine.
4. Start the engine and allow it to idle until the engine
coolant temperature reaches 70 – 80
C (158 –
176
F).
5. Hold the brake pedal down as far as it will go.
6. Place the selector in the “D” range.
7. Gradually push the accelerator pedal to the floor.
The throttle valve will be fully open.
Note the engine speed at which the tachometer
needle stabilizes.
Stall Speed : 2,100
150 rpm
NOTE: Do not continuously run this test longer than 5
seconds.
8. Release the accelerator pedal.
9. Place the selector in the “N” range.
10. Run the engine at 1,200 rpm for one minute.
This will cool the transmission fluid.
11. Repeat Steps 7 – 10 for the “3”, “2”, “L” and “R”
ranges.
Line Pressure Test
The line pressure test checks oil pump and control valve
pressure regulator valve function. It will also detect oil
leakage.
Line Pressure Test Procedure:
1. Check the level of the engine coolant, the engine oil,
and the automatic transmission fluid.
Replenish if required.
2. Block the wheels and set the parking brake.
3. Remove the pressure detection plug at the left side of
the transmission case.
Set 5–8840–0004–0 pressure gauge and adapter to
the pressure detection plug hole.
241RS001
4. Start the engine and allow it to idle until the engine
coolant temperature reaches 70 – 80
C (158 –
176
F).
5. Hold the brake pedal down as far as it will go.
6. Place the selector in the “D” range.
7. Note the pressure gauge reading with the engine
idling.
8. Gradually push the accelerator pedal to the floor. The
throttle valve will be fully open.
Note the pressure gauge reading with the accelerator
pedal fully depressed.
NOTE: Do not continuously run this test longer than 5
seconds.
9. Release the accelerator pedal.
10. Place the selector in the “N” range.
11. Run the engine at 1,200 rpm for one minute.
This will cool the transmission fluid.
12. Repeat Steps 7 – 11 for the “3”, “2”, “L”, and “R”
ranges.
13. Install a pressure detection plug to the transmission
case, applying recommended thread locking agent
(LOCTITE 242) or its equivalent to thread of plug.
Make sure that thread is cleaned before applying
locking agents.
14. Tighten the pressure detection plug to the specified
torque.
Torque:9–14Nꞏm(0.9–1.4kgꞏm/7–10lbft)

7A–37 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–40
AUTOMATIC TRANSMISSION (4L30–E)
Valve Body Assembly (Adapter Case)
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 sensor
connector.
6. Remove twelve 10 mm adapter case oil pan fixing
screws, adapter case oil pan, and gasket.
NOTE: Oil pan still contains transmission fluid. Place a
large drain container under the oil pan.
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 seven 13 mm screws from adapter case
valve body assembly, then remove transfer plate, two
gaskets, and adapter case valve body.
Installation
1. Inspect electrical 5 pin connector and seal of adapter
case. Replace if necessary.2. Install gasket, transfer plate, and gasket.
3. Install adapter case valve body and seven 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)
4. Connect wiring harness assembly to converter clutch
solenoid and force motor.
5. Install oil pan gasket, oil pan, and twelve 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 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)
7. Install transfer and exhaust protectors. Tighten the
bolts to the specified torque.
To r q u e : 3 7 N
m(3.8kgꞏm/27lbft)
8. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
9. Connect battery ground cable.
Powertrain Control Module (PCM)
Removal
1. Disconnect battery ground cable.
2. Remove front console.
3. Disconnect PCM wiring harness connectors from
PCM.
4. Remove three PCM retaining screws.
5. Remove two brackets from PCM.
826RV006
Installation
1. Install two brackets to PCM.
2. Install three PCM retaining screws.
3. Connect PCM wiring harness connectors to PCM.
4. Install front console.
5. Connect battery ground cable.

7A–41 AUTOMATIC TRANSMISSION (4L30–E)
Speed Sensor (Extension Housing)
Removal
1. Disconnect battery ground cable.
2. Remove front console.
3. Remove selector lever assembly.
4. Disconnect speed sensor harness connector from
speed sensor.
5. Remove one 10 mm screw and speed sensor with
O–ring.
241RW007
Installation
1. Inspect the speed sensor O–ring, and replace it if
necessary.
2. Install speed sensor assembly and 10 mm screw.
To r q u e : 9 N
m (0.9 kgꞏm/78 lb in)
3. Connect speed sensor harness connector to speed
sensor.
4. Install selector lever assembly.
Adjust shift lock cable. Refer to Selector Lever in
this section.
5. Install front console.
6. Connect battery ground cable.
Transmission Oil Temperature Sensor (Adapter Case)
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 sensor
connector.
6. Remove twelve 10 mm adapter case oil pan fixing
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,
converter clutch solenoid, and 5 pin connector of
adapter case. Pull only on connectors, not on wiring
harness.
8. Disconnect ground wire from converter clutch
solenoid wiring harness connector.
9. Remove wiring harness assembly (transmission oil
temperature sensor).
243RW002

7A–42
AUTOMATIC TRANSMISSION (4L30–E)
Installation
1. Connect ground wire to converter clutch solenoid
wiring harness connector of the wiring harness
assembly.
2. Install wiring harness assembly to converter clutch
solenoid, force motor, and 5 pin connector of adapter
case.
3. Install oil pan gasket, oil pan, and twelve 10 mm fixing
screws. Tighten the screws to the specified torque.
Torque: 11 N
m (1.1 kgꞏm/96 lb in)4. 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)
5. Install transfer and exhaust protectors. Tighten the
bolts to the specified torque.
To r q u e : 3 7 N
m (3.8 kgꞏm/27 lb ft)
6. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON
–III.
Refer to Changing Transmission Fluid in this section.
7. Connect battery ground cable.
Front Oil Seal (Converter Housing)
Removal
1. Remove transmission assembly with transfer case
from the vehicle. Refer to Transmission (with Transfer
Case) in this section.
2. Remove torque converter from converter housing.
3. Remove three screws and oil seal ring from converter
housing.
241RW008
Installation
1. Apply clean ATF to the new oil seal ring lip.
Install oil seal ring to converter housing. Tighten the
screws to the specified torque.
To r q u e : 3 N
m (0.3 kgꞏm/26 lb in)
2. Install torque converter to converter housing.
3. Install transmission assembly with transfer case to
the vehicle. Refer to Transmission (with Transfer
Case) in this section.

7A–43 AUTOMATIC TRANSMISSION (4L30–E)
Rear Oil Seal (Extension Housing)
Removal
1. Remove transfer case assembly from the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
2. Remove rear oil seal from transmission extension
housing.
241RW005
Installation
1. Use 5–8840–2282–0 (J–36797) extension housing
oil seal installer, and install the rear oil seal to the
transmission extension housing.
2. Install the transfer case assembly to the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
Transmission (4L30–E)
Disassembly
NOTE: During the disassembly and reassembly, perform
the following:
Wash each part thoroughly, and blow air through each
oil passage and groove to eliminate blockage.
Seal rings, roll pins, and gaskets should be replaced.
When assembling the components, apply
DEXRON
–III Automatic Transmission Fluid (ATF)
to each seal, rotating part, and sliding part.
Do not dip part facings, such as clutch or brake drive
plates, in cleaner when washing it.
Also, always coat parts with new ATF two or three
times after cleaning with solvent.
1. Remove torque converter (1).
Drain fluid from torque converter.
Attach 5–8840–2278–0 (J–8763–02) holding
fixture to the transmission and set it on
5–8840–0003–0 (J–3289–20) holding fixture base.
NOTE: Do not overtighten the tool, as case damage may
result.
420RW019
2. Remove O–ring (2) from turbine shaft.
3. Remove two 10mm mode switch screws, selector
lever nut, cover, and mode switch (3).
4. Remove twelve 10mm adapter case oil pan (4) fixing
screws, adapter oil pan, and gasket.
5. Disconnect electrical wiring connections (5) from
solenoids and 5 pin connector of adapter case. Pull
on connectors only, not on wiring harness.

7A–46
AUTOMATIC TRANSMISSION (4L30–E)
241RW004
24. Remove fourth clutch retainer (26).
25. Grasp turbine shaft and lift out the overrun clutch
housing assembly (27) and fourth clutch plates (28).
26. Remove thrust bearing assembly (29).
27. Remove overdrive internal gear (30).
28. Remove thrust washer (31).
252RS001
29. Remove adapter case and center support assembly
(with fourth clutch piston) (32).
30. Remove seal ring (33).
31. Remove selective thrust washer (34) and two O–ring
seals (35) from main case.
32. Use 5–8840–0195–0 (J–23327) and 5–8840–2263–0
(J–23327–90) compressor to compress the fourth
clutch spring retainer and springs (37).
Release snap ring (36) from groove.
Remove clutch compressor and snap ring (36).
33. Remove retainer and spring assembly (37).
34. Insert two converter housing/main case screws to
hold adapter case while pulling out fourth clutch
piston (38).
Remove fourth clutch piston assembly (38) from the
adapter case.
Remove converter housing/main case screws.
35. Grasp intermediate shaft, twist and pull out the
second and third clutch drum assemblies with reverse
clutch plates while holding onto output shaft (39).

7A–47 AUTOMATIC TRANSMISSION (4L30–E)
36. Separate second (40) and third clutch (41)
assemblies.
37. Remove thrust washer (42).
38. Remove reverse clutch plates (43 and 44) and
reverse clutch pressure plate (45).
39. Remove bearing (46) and washer (47).
40. Remove planetary carrier assembly (48).
41. Remove thrust bearing (49).
42. Remove reaction sun gear (50)
43. Remove needle bearing (51).
44. Remove brake drum (52).
45. Remove brake band (53).
46. Remove thrust bearing (54).
242RS003
47. Rotate case to horizontal position, valve body side
facing up.
Remove spring pin (55), using cutting pliers, then
remove parking lock and selector lever assembly
(56).NOTE: Insert wire in the center of the spring pin to
prevent it from collapsing during removal. Be aware of pin
height. Protect machined face of main case.
48. Remove parking lock and range selector lever 17 mm
nut (57).
49. Remove parking lock and range selector lever (56),
and actuator assembly.
50. Remove selector shaft (58).
NOTE: Inspect the shaft for burrs before removing to
prevent damaging seal. If necessary, remove burrs by
lightly sanding with an oilstone.
249RS004
Reassembly
1. Inspect selector shaft seal, and replace it if
necessary.
NOTE: Use a seal installer when replacing the seal.
Install selector shaft.
NOTE: Spring pin groove must be positioned inside the
case.
2. Install spring pin. Be sure the selector shaft can move
freely. Do not push the pin flush with the case surface.
Leave enough height for removal.
3. Install actuator assembly (1).
4. Install parking lock and range selector lever (2) and
new 17 mm nut. Tighten the nut to the specified
torque.
To r q u e : 2 2 N
m (2.2 kgꞏm/16 lb ft)

7A–48
AUTOMATIC TRANSMISSION (4L30–E)
249RS005
5. Rotate main case to vertical position, extension end
facing down.
Install brake band assembly (3).
NOTE: Be sure to align servo pin area with the servo hole.
6. Install thrust bearing (4).
NOTE: The case bushing acts as a guide for the thrust
bearing.
7. Install brake drum (5).
8. Install reaction sun gear (6).
9. Install needle bearing (7).
10. Inspect planetary carrier assembly (8) for wear and
damage. If necessary replace it.
Measure pinion end play clearance with a feeler
gauge.
Clearance: 0.13mm–0.89mm (0.005 in–0.035 in)
If clearance is outside specified value, replace the
planetary carrier assembly.
248RS001
11. Install the thrust bearing (9) on the output shaft.
NOTE: Use petroleum jelly to hold the thrust bearing in
place.
12. Align planetary pinions. Each pinion is marked with
double points to indicate the master tooth space and
exactly opposite with a single point to indicate the
master tooth. The markings on the planetary carrier
consist of double lines which are to be lined up with
the double points on two opposite pinions; the single
lines are to be lined up with the single points on the
other two pinions.
After all four pinions are lined up, slide on the third
clutch assembly. Rotate third clutch and check
mark alignment. Considering that the ring gear
tooth between the double points of one planetary
pinion is tooth number 1, count the teeth to check
that the single points on the two adjacent pinions
are between teeth 23 and 24 of the ring gear, and
that the ring gear tooth between the double points of
the opposite pinion is tooth number 46. If the ring
gear and pinions are not lined up, remove, and
realign them.
13. Install planetary carrier (8) with third clutch (12).
NOTE: Do not force. When properly aligned, the parts will
fit together easily.
248RS002
14. Remove the third clutch (12).
15. Install bearing (11) and washer (10).