brake OPEL FRONTERA 1998 Workshop Manual

7A–10
AUTOMATIC TRANSMISSION (4L30–E)
Checking Transmission Fluid Level
and Condition
Checking fluid level and condition (color and odor) at
regular intervals will provide early diagnosis information
about the transmission. This information may be used to
correct a condition that, if not detected early, could result
in major transmission repairs.
IMPORTANT:When new, automatic transmission fluid
is red in color. As the vehicle is driven, the transmission
fluid will begin to look darker in color. The color may
eventually appear light brown.
A dark brown color with burnt odor may indicate
excessive fluid deterioration and signal a need for fluid
change.
Fluid Level
When adding or changing fluid, use only DEXRON –III.
Refer to Maintenance and Lubrication in General
Information section for maintenance information and
servicing interval.
CAUTION: DO NOT OVERFILL.
Overfilling will cause foaming, loss of fluid, abnor-
mal shifting and possible damage to the transmis-
sion.
1. Park the vehicle on level ground and apply the parking
brake firmly.
2. Check fluid level with engine running at idle.
NOTE: Be sure that transmission fluid temperature is
below 30
C (86F).
3. Move the selector lever through all gear ranges.
4. Move the selector lever to “Park”.
5. Let engine idle for 3 minutes and open the overfill
screw (1).
6. Add released transmission fluid until it flows out over
the overfill screw opening.
7. Let engine idle until a fluid temperature between 32
C
(90
F) and 57C (135F) is reached, then close the
overfill screw (1).
Torque: 38 N
m (3.9 kgꞏm/28 lb ft)
NOTE: To prevent fluid leaks, the overfill screw and oil
drain screws gasket must be replaced each time these
screws are removed.NOTE: Check transmission fluid temperature with scan
tool.
Minimum fluid level
57C (135F)
Maximum fluid level
32C (90F)
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CAUTION: Do not open overfill screw with engine
stopped.
CAUTION: DO NOT CHECK FLUID LEVEL UNDER
THESE CONDITIONS:
Immediately after driving at sustained highway
speeds.
In heavy city traffic during hot weather.
If vehicle is towing a trailer.
If the vehicle has been operated under these conditions,
shut the engine off and allow the vehicle to “cool” for thirty
(30) minutes. After the cool down period, restart the
vehicle and continue from step 2 above.

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
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–14
AUTOMATIC TRANSMISSION (4L30–E)
Chart 2: No Forward Gears In Any Range/No Reverse
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 internal linkage:
– Manual linkage (58) not moving manual valve (326).
2. Check for internal mechanical damage:
– Turbine shaft (506) broken loose.
– Overrun roller clutch (516) broken loose.
Was the problem found?
Repair or replace—
Chart 3: No Engine Brake In Any Range
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 overrun clutch leaks caused by:
– Damaged piston lip (513)
– Check ball defective (504)
2. Check for overrun lockout valve (705) stuck by foreign
material.
3. Check for leaks at turbine shaft (506) caused by:
– Teflon seal rings damaged (508)
– Excessive wear of turbine shaft bearing surfaces.
Was the problem found?
Repair or replace—

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–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–29 AUTOMATIC TRANSMISSION (4L30–E)
256RW015
3. Check the shift lock operation:
a. Selector lever should not move out of “P” position
with ignition key in “Lock” position.
b. Selector lever can be moved out of “P” position with
ignition key in “ON” position only when brake pedal
is depressed.
c. Ignition key can be turned to “LOCK” position only
when selector lever is in “P” position (key can be
pulled out).
If (a) and (c) fail, readjust cable. If (b) fails, readjust
connector wiring and brake pedal switch.
Mode Switch
Removal
1. Place selector lever in neutral.
2. Disconnect battery ground cable.
3. Remove mode switch cover (1).
4. Disconnect selector lever (2) from the mode switch.
5. Disconnect transmission harness from the mode
switch connector (3).
6. Remove bracket with mode switch connector from
the transmission case.
7. Remove mode switch connector (3) from the bracket
(4).
8. Remove two mode switch bolts and nut then remove
mode switch (5).
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Installation
To install, follow the removal steps in the reverse order,
noting the following points;
1. Torque
Mode switch bolt: 13 N
m(1.3kgꞏm/113lbin)
Selector lever nut: 23 N
m (2.3 kgꞏm/17 lb ft)
2. Mode switch setting procedure
Perform either of the following adjustment
procedures:
Procedure 1
a. Place selector lever in neutral.
b. Remove selector lever from the mode switch.
c. Remove the mode switch cover.
d. Loosen the two 10 mm screws.
e. Rotate the mode switch until the slot in the mode
switch housing aligns with the selector shaft
bushing, and insert a 3/32 in. (2.4 mm) drill bit or
punch (1) into the slot.
f. Tighten the screws to 13 Nꞏm (1.3 kgꞏm/113 lb in).
g. After completing adjustment, snap the mode
switch cover into place.
h. Reinstall the selector lever.

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.
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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.
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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–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).

7A–54
AUTOMATIC TRANSMISSION (4L30–E)
241RW009
241RW019
43. Main case end play measurement.
1. Attach axial play checking tool on the extension
housing and set indicator to zero on output shaft.
2. Manually push output shaft upwards.
End play: 0.36mm – 0.80mm (0.014 in – 0.031in)
3. Remove axial play checking tool.
4. If end play is not correct, repeat selective washer
selection.
241RS005
44. Inspect servo piston seal ring. Replace if necessary.
Ensure brake band is correctly positioned. Rotate
output shaft if necessary.
Install 5–8840–2274–0 (J–38428) servo piston
fitter in servo bore.
Install apply rod (40), round end toward band, return
spring (41) and piston assembly (42).
45. Install the 5–8840–0501–0 (J–23075) servo spring
compressor with offset to rear of case.
Compress servo piston seal ring, using fitter while
tightening the tool screw.
Install servo piston retaining ring (43).
Remove tool.
Adjust the brake band by tightening the servo
adjusting screw to 4.5 Nꞏm torque. Be certain the
lock nut is loose, then back–off the screw five turns
exactly. Hold piston sleeve with wrench and tighten
lock nut to 18.5 Nꞏm torque. Be certain the adjusting
screw does not turn.