manual transmission OPEL FRONTERA 1998 Workshop Manual

7A–47 AUTOMATIC TRANSMISSION (4L30–E)
6. Remove seven 13mm adapter case valve body (6)
fixing screws, adapter case valve body assembly,
transfer plate, and two gaskets.
Remove wiring harness and 5 pin connector.
7. Remove sixteen 10mm main case oil pan (7) fixing
screws, main oil pan, magnet, and gasket.
8. Remove three 13mm oil filter (8) fixing screws and oil
filter.
9. Remove two 13mm manual detent (9) fixing screws,
roller and spring, and manual detent.
10. Disconnect wiring harness assembly (10) from band
apply solenoid, shift solenoids, and main case 4 pin
connector.
Pull on connectors only, not on wiring harness.11. Remove four 13mm servo cover (11) fixing screws,
servo cover, and gasket.
12. Remove seven 13mm valve body screws and ground
wire from main case.
Remove wiring harness assembly (5) from the
adapter case side.
Remove main valve body assembly (12) with
manual valve link and transfer plate. Note the
position of the link (long end into valve, short end
into range selector lever).
Remove 4 pin connector.
Remove gasket transfer plate from main case.
13. Remove two check balls (13) from main case.
240RW022
14. Turn transmission to vertical position to drain fluid.
Return back to horizontal position when drained.
Install 5–8840–0501–0 (J–23075) servo piston
spring compressor with offset to the rear of case.
Compress servo piston assembly.
Remove servo piston retaining ring (14).
Slowly release servo piston assembly (15).
Remove tool.

7A–57 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.

7A–58
AUTOMATIC TRANSMISSION (4L30–E)
242RW008
46. Install two check balls (44).
244RW002
47. Inspect main case electrical connector and seal,
replace if necessary.
Install electrical 4 pin connector/main case and
wiring harness.
48. Install two 5–8840–0022–0 (J–25025–B) guide pins
into main case.
Install main case valve body complete assembly
(45) 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.
Install seven 13 mm screws.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
Pass ground wire of adapter case wiring harness
assembly through the hole joining adapter fluid area
and main case fluid area.
Assemble 8.5 mm connector of ground wire under
the head of this valve body bolt and reinstall it.
Remove two guide pins.
244RW001
49. Install servo cover gasket, cover (46) and four 13 mm
screws.
To r q u e : 2 5 N
m (2.6 kgꞏm/18 lb ft)
50. Connect wiring harness (47) to band control, shift
solenoids, and main case 4 pin connector.
51. Install manual detent roller and spring assembly (48)
with clip.
Install two 13 mm screws.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
52. Install oil filter (49), and three 13 mm screws.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
53. Install oil pan gasket, magnet, main oil pan (50), and
sixteen 10 mm screws.
To r q u e : 11 N
m (1.1 kgꞏm/96 lb in)
54. Inspect adapter case electrical connector and seal.
Replace if necessary.
Install electrical five pin connector and harness
assembly (52) in bottom of adapter case.
55. Install gasket, transfer plate, and gasket.
Install adapter case valve body (51) and seven 13
mm screws.
Torque: 20 N
m (2.0 kgꞏm/15 lb ft)

7A–62
AUTOMATIC TRANSMISSION (4L30–E)
Main Case Valve Body
Disassembled View
244RS010
Legend
(1) Gaskets and Transfer Plate
(2) Manual Valve
(3) Band Control Solenoid
(4) Pin
(5) Waved Washer
(6) Spring Pin
(7) Solenoid A
(8) Retainer
(9) 1–2/3–4 Shift Valve
(10) Spring
(11) Spring Pin
(12) Solenoid B
(13) Retainer
(14) 2–3 Shift Valve(15) Spring
(16) Spring Pin
(17) Plug
(18) Spring
(19) Low Pressure Control Valve
(20) Spring Pin
(21) Plug
(22) Band Control Screen Assembly
(23) Spring Pin
(24) Plug
(25) 1–2 Accumulator Valve
(26) 1–2 Accumulator Control Valve
(27) Check Ball
(28) Main Case Valve Body
Disassembly
1. Remove two 11mm bolts from valve body (28), then
remove gaskets and transfer plate (1).
2. Remove manual valve (2).
3. Push in band control solenoid (3) to compress waved
washer (5), and remove pin (4).
4. Remove band control solenoid (3) and waved washer
(5).5. Remove spring pin (6) with a 3 mm dia punch.
6. Remove solenoid A (7) by grasping the metal tip. Do
not grasp the connector housing.
7. Remove retainer (8), 1–2/3–4 shift valve (9), and
spring (10).
8. Remove spring pin (11) with a 3 mm dia punch.
9. Remove solenoid B (12) by grasping the metal tip. Do
not grasp the connector housing.

7A–63 AUTOMATIC TRANSMISSION (4L30–E)
10. Remove retainer (13), 2–3 shift valve (14), and spring
(15).
11. Remove spring pin (16), plug (17), spring (18), and
low pressure control valve (19).
12. Remove spring pin (20), plug (21), and band control
screen assembly (22).
13. Remove spring pin (23), plug (24), 1–2 accumulator
valve (25), and 1–2 accumulator control valve (26).
14. Remove check ball (27) from valve body (28).
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 1–2 accumulator control valve (26), 1–2
accumulator valve (25), plug (24), and spring pin (23).
2. Install band control screen assembly (22), plug (21),
and spring pin (20).
3. Install low pressure control valve (19), spring (18),
plug (17), and spring pin (16).
4. Install spring (15), 2–3 shift valve (14), retainer (13),
solenoid B (12), and spring pin (11).
5. Install spring (10), 1–2/3–4 shift valve (9), retainer (8),
solenoid A (7), and spring pin (6).
6. Install waved washer (5), band control solenoid (3),
and pin (4).
7. Install manual valve (2).
8. Install check ball (27) to valve body (28).9. Install gasket (valve body/transfer plate) and transfer
plate using two 5–8840–2270–0 (J–3387–2) guide
pins.
Install two 11mm bolts.
To r q u e : 1 3 N
m (1.3 kgꞏm/113 lb in)
244RW004
Install gasket (transfer plate/main case).

7A–87 AUTOMATIC TRANSMISSION (4L30–E)
(38) Seal, O–Ring
(39) Reservoir
(42) Gasket, Extension Case
(43) Extension Assembly
(44) Seal, O–Ring/Speed Sensor
(45) Sensor Assembly, Speed
(46) Screw, Speed Sensor
(50) Seal, Extension Assembly
(52) Screw, Extension/Main Case
(53) Spring, Parking Pawl Lock
(54) Pawl, Parking Lock
(55) Connector, Electrical/Main Case
(56) Actuator Assembly, Parking Lock
(57) Nut, Parking Lock Lever
(58) Link, Manual Valve
(59) Pin, Spring
(60) Lever, Parking Lock and Range Selector
(61) Shaft, Selector
(62) Seal, Selector Shaft
(63) Mode Switch Assembly
(64) Screw and Conical Washer Assembly
(65) Shield, Mode Switch
(67) Pan, Bottom/Adapter Case
(68) Gasket, Bottom Pan/Adapter Case
(69) Harness Assembly, Adapter Case
(70) Screw, Valve Body
(71) Valve Body Assembly, Adapter Case
(72) Gasket, Adapter Valve Body
(73) Plate, Adapter Valve Body/Transfer
(74) Pan, Bottom/Main Case(75) Gasket, Bottom Pan/Main Case
(76) Gasket, Oil Drain or Overfill Screw
(77) Screw, Oil Drain or Overfill
(78) Magnet, Chip Collector
(79) Filter Oil
(80) Harness Assembly, Main Case
(82) Roller and Spring Assembly, Manual Detent
(84) Valve Body Assembly, Main Case
(85) Ball, Check
(86) Gasket, Main V.B./Transfer Plate
(87) Plate, Main V.B./Transfer
(88) Gasket, Transfer/Main Case
(89) Screw, Transfer Plate on V.B.
(90) Screw, Servo Cover
(91) Cover, Servo Piston
(92) Gasket, Cover/Servo Piston
(93) Ring, Retaining Servo Piston
(94) Clip, Servo Piston
(95) Nut, Servo Screw
(96) Screw, Servo Piston
(97) Piston, Servo
(98) Seal, Ring/Servo Piston
(99) Spring, Cushion/Servo Piston
(100) Seat, Cushion Spring
(101) Sleeve, Servo Piston Adjust
(102) Rod, Apply/Servo Piston
(103) Spring, Return/Servo Piston
(104) Gasket, Adapter Case/Transfer Plate
(105) Powertrain Control Module
(106) Servo Piston Assembly
Pump Assembly
241RS019
Legend
(201) Gear, Oil Pump Drive
(202) Gear, Oil Pump Driven
(203) Pin, Boost Valve Sleeve
(204) Sleeve, Boost Valve(205) Valve, Boost
(206) Seat, Spring/Pressure Regulator Valve
(207) Spring, Pressure Regulator Valve
(208) Valve, Pressure Regulator
(209) Pump Assembly, Oil

7A–88
AUTOMATIC TRANSMISSION (4L30–E)
(210) Valve, Converter Clutch Control
(211) Spring, Converter Clutch Control Valve
(212) Plug, Converter Clutch Control Valve
(213) Pin, Spring(214) Piston, Throttle Signal Accumulator
(215) Spring, Throttle Signal Accumulator
(216) Seat, Spring/Throttle Signal Accumulator
(217) Ring, Snap/Throttle Signal Accumulator
Valve Body Assemblies
244RS009
Legend
(301) Body, Valve Main Case
(302) Pin, Spring
(303) Solenoid Assembly, ON/OFF N.C.
(304) Valve, 1–2 and 3–4 Shift
(305) Spring, 1–2 and 3–4 (2–3) Shift
(306) Retainer, Valve
(307) Solenoid Assembly, ON/OFF N.O.
(308) Valve, 2–3 Shift
(309) Pin, Spring
(310) Plug, Valve Bore(311) Spring, Valve Low Pressure Control
(312) Valve, Low Pressure Control
(317) Ball, Check
(318) Valve, 1–2 Accumulator Control
(320) Valve, 1–2 Accumulator
(321) Washer, Waved PWM Solenoid
(322) Pin, Solenoid PWM
(323) Solenoid Assembly, Band Control PWM
(324) Screen Assembly, PWM Solenoid
(325) Plug, Screen
(326) Valve, Manual

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–1
SECTION 7A
CONTENTS
AUTOMATIC TRANSMISSION (AW30-40LE)
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–3
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–3
ELECTRONIC CONTROL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–4
TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–5
CONTROL SYSTEM DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–6
CONTROL AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–7
MAJOR INPUT/OUTPUT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–9
LOCATION OF CLUTCH, BRAKE ONE-WAY CLUTCH AND SOLENOID . . . . . . . . . . . . . . . . . . . . . . . 7A–10
OPERATION OF CLUTCH, BRAKE AND ONE-WAY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–11
SPEED CHANGE AND LOCK-UP PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–11
OVERDRIVE AND LOCK-UP OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–12
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–13
BASIC TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–13
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–14
DIAGNOSIS WITH TECH2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–17
TECH2 CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–18
TECH2 OPERATING FLOW CHART (START UP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–19
TRANSMISSION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–21
TCC DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–22
INTERMITTENT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–23
IDENTIFICATION OF TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–24
DIAGNOSTIC TROUBLE CODES (DTC) CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–25
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–52
CONNECTOR LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–54
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–56
MANUAL SHIFTING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–62
STALL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–63
TIME LAG TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–64
HYDRAULIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–65
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–66
SHIFT POINT CHART AND LOCK-UP POINT CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–69
TCM VOLTAGE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–71
TCM STANDARD VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–72
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–75
TRANSIMISSION FLUID LEVEL AND CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–75
ATF REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–75
NEUTRAL START SWITCH INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–76
BRAKE SIGNAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–77
VEHICLE SPEED SENSOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–77
INPUT AND OUTPUT REVOLUTION SENSOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–77
PATTERN SELECT SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–78
OVERDRIVE OFF SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–78
SOLENOID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–78
THROTTLE POSITION SENSOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–79
ATF TEMPERATURE SENSOR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–79
SELECTOR LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–80
TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–81
SHIFT SOLENOID AND LOCK-UP SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–83

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.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–23
INTERMITTENT CONDITIONS
If the Tech2 displays a code as intermittent, or if after a
test drive a code does not reappear, the problem is most
likely a faulty electrical connection or loose wiring.
Terminals should always be the prime suspect.
Intermittent rarely occur in sophisticated electronic
components such as the Transmission Control Module
(TCM).
When an intermittent problem is encountered, check
suspect circuits for:
• Poor terminal to wire connection.
• Terminals not fully seated in the connector body
(backed out).
• Improperly formed or damaged terminals.
• Loose, dirty, or corroded ground connections.
HINT: Any time you have an intermittent in more than
one circuit, check whether the circuits share a
common ground connection.
• Pinched or damaged wires.
• Electro-Magnetic Interference (EMI)
HINT: Check that all wires are properly routed away
from spark plug wires, distributor wires, coil,
and generator. Also check for improperly
installed electrical options, such as lights, 2-
way radios, etc.
Use the F2: SNAPSHOT mode of the Tech2 to help
isolate the cause of an intermittent fault. The snapshot
mode will record information before and after the
problem occurs. Set the snapshot to "trigger" on the
suspect code (or codes) or, if you notice the repor ted
symptom during test drive, trigger the snapshot
manually.
After the snapshot has been triggered, command the
Tech2 to play back the flow of data recorded from each
of the various sensors. Signs of an intermittent fault in a
sensor circuit are a sudden unexplainable jump in data
values out of the normal range.