clutch OPEL FRONTERA 1998 Workshop Manual

7A–49 AUTOMATIC TRANSMISSION (4L30–E)
NOTE: Use petroleum jelly to hold the washer and
bearing in place.
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16. Carefully align the second clutch plate inner tangs.
Install thrust washer, tangs pointing downward, and
locating tang positioned in slot on second clutch
hub.
NOTE: Use petroleum jelly to hold thrust washer in place.
17. Install third clutch and intermediate shaft assembly
(13) into the second clutch drum (14).
18. Install second and third clutch assemblies into the
main case. Twist output shaft and clutch assemblies
to ensure proper fit.
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19. Install pressure plate (15) with lip side up, tang facing
valve body face.
20. Install reverse clutch plates. Start with a steel plate
(17) and alternate with a lined plate (16).
21. Install waved clutch plate (18) with center tang facing
valve body side.
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7A–50
AUTOMATIC TRANSMISSION (4L30–E)
22. Second clutch end play measurement
1. Install the 5–8840–2262–0 (J–23085–A)
Selective washer gauging tool (with spacer ring)
on the case flange and against the intermediate
shaft.
2. Position the inner shaft of the gauging tool against
the thrust surface of the second clutch hub.
3. Tighten thumb screw. Remove the tool.
4. Fit the spacer ring on the inner shaft of the tool.
5. Measure the gap, and select the appropriate
washer as shown in the chart.
Selective Thrust Washer
Gap: mm(in)Color
1.53 – 1.63 (0.060 – 0.064)Yellow
1.72 – 1.82 (0.068 – 0.072)Red
1.91 – 2.01 (0.075 – 0.079)Black
2.10 – 2.20 (0.083 – 0.087)Natural
2.29 – 2.39 (0.090 – 0.094)Green
2.48 – 2.58 (0.098 – 0.102)Blue
FOLLOWING THE PROCEDURE SHOULD RE-
SULT IN FINAL END–PLAY FROM 0.36 mm TO
0.79 mm (0.014 in TO 0.031 in)
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23. Inspect fourth clutch piston seals and replace if
necessary.
Lubricate 5–8840–2267–0 (J–38554) fourth clutch
piston fitter and install it on fourth clutch piston (19).
Install fourth clutch piston (19) in adapter case (20).
Remove fitter.
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24. Install retainer and spring assembly (22) into fourth
clutch piston (21).

7A–51 AUTOMATIC TRANSMISSION (4L30–E)
25. Install snap ring (23) in adapter case.
Install 5–8840–0195–0 (J–23327) and
5–8840–2263–0 (J–23327–90) fourth clutch spring
compressor.
Seat snap ring in groove.
Remove compressor.
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26. Install selective washer using petroleum jelly.
27. Install two O–ring seals (24) in main case and adapter
case/main case seal ring (25).28. Install 5–8840–2268–0 (J–38588) guide pins.
Install adapter case and center support assembly to
main case.
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29. Install thrust washer (26) into adapter case, with
tangs pointing downwards.
30. Preassemble overdrive internal gear (27) and thrust
bearing assembly (28) onto the turbine shaft and
overrun clutch assembly.
NOTE: Install bearing assembly, black side up. Use
petroleum jelly to keep assembly in place.
31. Install overdrive carrier (30) and internal gear
assembly into adapter case.
32. Install fourth clutch plates (29) in the following order:
Steel, Lined, Steel, Steel, Lined, Steel. Steel plates
go in with short tang facing towards valve body
surface.

7A–52
AUTOMATIC TRANSMISSION (4L30–E)
33. Install fourth clutch retainer (31) with the notch facing
up and positioned towards valve body surface.
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34. Overdrive clutch end play measurement
1. Install the 5–8840–2262–0 (J–23085–A)
selective washer gauging tool on the adapter
case flange and against the input shaft.
2. Position the inner shaft of the tool against the
thrust surface of the overrun clutch housing.
3. Tighten thumb screw. Remove the tool.
4. Measure gap. Select appropriate size washer as
shown in the chart.
5. Set selective thrust washer aside.
Selective Thrust Washer
Gap: mm(in)Color
1.53 – 1.63 (0.060 – 0.064)Yellow
1.72 – 1.82 (0.068 – 0.072)Red
1.91 – 2.01 (0.075 – 0.079)Black
2.10 – 2.20 (0.083 – 0.087)Natural
2.29 – 2.39 (0.090 – 0.094)Green
2.48 – 2.58 (0.098 – 0.102)Blue
FOLLOWING THE PROCEDURE SHOULD RE-
SULT IN FINAL END–PLAY FROM 0.1 mm TO 0.8
mm (0.004 in TO 0.03 in)
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35. Install selective washer (32).
NOTE: Use petroleum jelly to hold selective washer in
place.
36. Install gasket (33).
37. Install converter housing and oil pump assembly (34)
to adapter case.
Fit and tighten seven outer 13 mm screws.
To r q u e : 3 9 N
m (4.0 kgꞏm/29 lb ft)

7A–53 AUTOMATIC TRANSMISSION (4L30–E)
Ensure free rotation of pump using 5–8840–2273–0
(J–23082–01) oil pump rotation tool.
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38. Overdrive clutch end play measurement.
1. Fit 5–8840–2271–0 (J–25022) and
5–8840–0618–0 (J–24773–1) turbine shaft puller
on turbine shaft.
2. Position axial play checking tool on converter
housing mating face.
3. Pull turbine shaft upwards with puller until first
resistance is met. (due to weight of overdrive
assembly).
4. Maintain shaft in this position and set indicator to
zero.
5. Pull turbine shaft further upwards with puller.
Read end play shown on indicator.
End play: 0.1mm – 0.8mm (0.004 in – 0.031in)6. Remove axial play checking tool and puller.
NOTE: If end play is not correct, repeat selective washer
selection.
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39. Inspect extension housing oil seal and replace if
necessary, using 5–8840–2282–0 (J–36797)
extension housing oil seal installer.
Rotate transmission to horizontal position, with
valve body side down.
Inspect parking wheel seal ring. Replace if
necessary.
Install wheel parking lock assembly (35).
40. Install speed wheel (36) and snap ring (37).
NOTE: Use extra long, needle-nose pliers.
41. Install gasket onto extension assembly with a thin
coating of oil.
Install extension housing assembly (38), and align
parking pawl shaft.
Install actuator assembly into extension assembly.
Install seven 8 mm hexagon socket head screws.
To r q u e : 3 2 N
m (3.3 kgꞏm/24 lb ft)
42. Inspect speed sensor O–ring. Replace if necessary.
Install speed sensor assembly (39) and 10 mm
screw.
To r q u e : 9 N
m (0.9 kgꞏm/78 lb in)

7A–56
AUTOMATIC TRANSMISSION (4L30–E)
56. Connect wiring harness harness assembly (52) to
converter clutch solenoid, force motor, and 5 pin
connector.
57. Install oil pan gasket, adapter case oil pan (53), and
twelve 10 mm screws.
Torque: 11 N
m (1.1 kgꞏm/96 lb in)
Rotate transmission, with bottom pan facing down.
58. Install mode switch (54), two 10 mm screws, selector
lever nut, and cover.
10 mm screw
Torque: 13 N
m (1.3 kgꞏm/113 lb in)
Nut
Torque: 23 N
m (2.3 kgꞏm/17 lb ft)
Adjust using setting tool, refer to Mode Switch in
this section.
59. Install O–ring (55) on turbine shaft.60. Install torque converter (56)
The converter assembly must be replaced under any
of the following conditions:
a. Evidence of damage to the pump assembly.
b. Metal particles are found after flushing the cooler
lines.
c. External leaks in hub weld area.
d. Converter pilot broken, damaged, or poor fit into
crankshaft.
e. Converter hub scored or damaged.
f. Internal failure in stator.
g. Contamination from engine coolant.
h. Excess end play.Rotate transmission, bell housing up. Spin
converter to insure proper fit.
61. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
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7A–58
AUTOMATIC TRANSMISSION (4L30–E)
Oil Pump
Disassembled View
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Legend
(1) Oil Pump Drive Gear
(2) Oil Pump Driven Gear
(3) Pin
(4) Plug
(5) Spring
(6) Converter Clutch Control Valve
(7) Snap Ring
(8) Spring Seat
(9) Spring(10) Throttle Signal Accumulator Piston
(11) Sleeve Pin
(12) Sleeve
(13) Boost Valve
(14) Spring Seat
(15) Valve Spring
(16) Spring Seat
(17) Pressure Regulator valve
(18) Oil Pump Assembly
Disassembly
1. Remove oil pump drive gear (1) and driven gear (2).
2. Remove pin (3) from oil pump assembly (18).
3. Remove plug (4), spring (5), and converter clutch
control valve (6).
4. Remove snap ring (7) from oil pump assembly (18).
5. Remove spring seat (8), spring (9), and throttle signal
accumulator piston (10).
6. Remove sleeve pin (11) from oil pump assembly (18).
7. Remove sleeve (12), boost valve (13), spring seat
(14), valve spring (15), spring seat (16), and pressure
regulator valve (17).
Inspection And Repair
Visual Check:
If any damage, deformation or wear is found, replace the
damaged part.
Reassembly
1. Lubricate and preinstall pressure regulator spring
seat (16) on valve (17), with the flat side against
shoulder.
2. Install pressure regulator valve (17) and spring seat
(16) assembly, valve spring (15), and spring seat (14)
with the flat side away from spring to oil pump
assembly (18).
3. Assemble boost valve (13) into sleeve (12).
4. Install boost valve and sleeve assembly, and sleeve
pin (11) to oil pump assembly (18).
5. Install throttle signal accumulator piston (10), spring
(9), and spring seat (8), with the flat side away from
the spring, and snap ring (7) to oil pump assembly
(18).
6. Install converter clutch control valve (6), spring (5),
plug (4), and pin (3) to oil pump assembly (18).
7. Install oil pump driven gear (2) and drive gear (1).

7A–61 AUTOMATIC TRANSMISSION (4L30–E)
Adapter Case Valve Body
Disassembled View
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Legend
(1) Converter Clutch Solenoid Assembly
(2) Retainer
(3) Force Motor Solenoid
(4) Retainer
(5) Plug
(6) 3/4 Accumulator Valve
(7) 3/4 Accumulator Control Valve(8) Spring
(9) Retaining Ring
(10) Feed Limit Valve
(11) Plug Retainer
(12) O–Ring
(13) Plug
(14) Force Motor Screen Assembly
(15) Adapter Case Valve Body
Disassembly
1. Remove 11mm bolt from valve body.
Remove converter control solenoid assembly (1).
2. Remove 11mm bolt and retainer (2) from valve body.
Remove force motor solenoid (3).
3. Remove retainer (4), plug (5), 3/4 accumulator valve
(6), and 3/4 accumulator control valve (7).
4. Remove spring (8), retaining ring (9), and feed limit
valve (10).
5. Remove plug retainer (11), O–ring (12), plug (13), and
force motor screen assembly (14).
Use 5 mm bolt to pull plug.
Inspection And Repair
Inspect for the following, and replace any damaged or
worn parts:
1. Damage or wear to each valve.
2. Damage in oil passeges.
3. Cracks or damage to valve body.
4. Valve operations.
5. Spring fatigue.
Reassembly
1. Install force motor screen assembly (14), plug (13),
O–ring (12), and plug retainer (11).
2. Install feed limit valve (10), retaining ring (9), and
spring (8).

7A–62
AUTOMATIC TRANSMISSION (4L30–E)
3. Install 3/4 accumulator control valve (7), 3/4
accumulator valve (6), plug (5), and retainer (4).
4. Install force motor solenoid (3).
Place solenoid terminals pointing towards mating
face.
Install retainer (2) and bolt.
Torque: 10 N
m (1.0 kgꞏm/87 lb in)
5. Install converter clutch solenoid assembly with two
O–rings (1) to valve body.
Install bolt.
Torque: 10 N
m (1.0 kgꞏm/87 lb in)

7A–63 AUTOMATIC TRANSMISSION (4L30–E)
Third Clutch And Sprag Unit
Disassembled View
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Legend
(1) Retaining Ring
(2) Input Sun Gear and Sprag Unit Assembly
(3) Retaining Washer
(4) Bearing(5) Thrust Washer
(6) Clutch Plates
(7) Third Clutch Spring Cushion Plate
(8) Third Clutch Drum Assembly
Disassembly
1. Place the third clutch drum and intermediate shaft
assembly upright, using the overdrive internal gear as
a support.
2. Locate the ends of the retaining ring. Depress one
end of the ring using a small screwdriver instead of
the depressor handle provided with the tool
5-8840-2258-0 (J-38450-A). Slide one blade down
between the third clutch drum and the retaining ring.
3. Remove a screwdriver and repeat this step for the
other end of retaining ring.
4. Install the remaining four blades approximately (five)
notches apart using a screwdriver to depress the
retaining ring.
5. Pull up on input sun gear and sprag unit assembly (1
and 2) to release the retaining ring from third clutch
drum assembly (8).
6. Remove the tool blades.
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7. Remove retaining washer (3), bearing (4), thrust
washer (5), and clutch plates (6 and 7) form the third
clutch drum assembly (8).