manual transmission OPEL FRONTERA 1998 Workshop Manual

7A–30 AUTOMATIC TRANSMISSION (AW30-40LE)
DTC P0705 (FLASHING CODE 17) GEAR SELECTOR FAILURE (PRND2L)
D07RY00022Circuit description:
The neutral start switch gives the signals related to the
selector lever position (PRND2L) to the Transmission
Control Module (TCM). The neutral star t switch turns on
when the select lever is shifted to the P, R, N, D, 2 or L
range. The neutral star t switch, which is connected to the
starter switch circuit, is available only when the select
lever is in the P or N range
The neutral start switch is connected to the transmission
manual shaft and installed in the transmission case.
Fail-safe condition:
The TCM controls fail-safe by detecting selector position
switch fail ure.
Failure detection:
(1) OPEN:
• When all switches are OFF
• When the failure criteria continues for 30 seconds
if the vehicle speed which is calculated by output
revolution sensor is more than 30 km/h and the
engine revolution is more than 1500 rpm.
(2) SHORT:
• When more than two switches are ON at the same
time.
• When the failure criteria condition for 10 seconds.
Contents of control:
At failure detection
(1) OPEN: D range judgment
(2) SHORT: Judged by priority D>2>L>R>N>P
•Up hill and down hill control inhibit
•Winter mode inhibitAt failure decision
Excutes following items in addition to above control
items at failure detection.
•Blinks "CHECK TRANS" lamp
•Stores the failure information in failure-memory
•Reverse lockout control inhibit
Conditions of turning “CHECK TRANS” off:
Turns “CHECK TRANS” lamp off when only one of all
switches is ON.
Reversion conditions from fail-safe:
Turns “CHECK TRANS” lamp off when only one of all
switches is ON.
Test description:
The following numbers correspond to circled numbers on
the diagnostic char t.
(1) It is judged whether the input signal received from
the neutral star t switch by the TCM is proper or not.
(2)The power status of the neutral start switch is
checked.
(3) The continuity between neutral star t switch terminals
and the continuity of the wire connected to the
neutral start switch are checked.
Diagnostic aids:
An intermittent may be caused by a poor connection,
rubbed through wire insulation or a wire broken inside
the insulation. Inspect related harness connector for
backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals, poor terminal
to wire connection and damaged harness.

7A–40 AUTOMATIC TRANSMISSION (AW30-40LE)
DTC P0743 (FLASHING CODE 33) TORQUE CONVERTER CLUTCH CONTROL LOCK-UP (ON/
OFF) SOLENOID FA I L U R E ( S L )
D07RY00047Circuit description:
The lock-up solenoid SL of the torque converter clutch
(TCC) controls the lock-up clutch by a signal according to
the lock-up range judgement of the TCM when the
vehicle runs.
This function can improve the fuel consumption to almost
the same extent as the manual transmission. The lock-up
solenoid SL is put into B+ by the TCM, so that the
solenoid is actuated with the result of lock-up.
Fail-safe control:
The TCM controls fail-safe by detecting SL solenoid
fai lu re.
Failure detection:
GND SHORT detection
•When SHORT detection continues for 0.3 sec.
•When SHORT failure detection continues 8 times.
Open detection
•When OPEN detection continues for 0.5 sec.
•When OPEN failure detection continues 8 times.
Contents of control:
At failure detection
• Lock-up control inhibit
• If + B short failure is detected, keeps 1st gear when
the vehicle speed calculated by output revolution
sensor is less than 10km/h to prevent stall.
(Canceled at more than 15km/h)
At failure decision
Executes following items in addition to above control
items at failure detection.
•Stores the failure information in failure-memory.
Conditions of turning “CHECK TRANS” lamp off:
NoneReversion conditions from fail-safe:
When a normal condition is judged by rechecking on the
state of lock-up ON/OFF
Test description:
The following numbers correspond to circled numbers on
the diagnostic char t.
(1) When the key is ON, the voltage between the TCM
connector terminals (C78-12) and (C78-15 or 19) is
1.0 V or less.
(2) When the gear is of the 2nd speed in the D range
and the throttle opening is about 50% at a higher
speed than about 40km/h, the TCM supplies 8 to 16
V, so that the solenoid is actuated with the result of
lock-up.
(3) The resistance range of the solenoid is 11 to 15
.
Diagnostic aids:
In case of faulty connection, open or shorted circuit. to
the TCM terminal (C78-12), DTC P0743 is displayed. A
intermittent failure may be caused by a poor connection,
rubbed through wire insulation or a wire broke inside the
insulation.

7A–62 AUTOMATIC TRANSMISSION (AW30-40LE)
826RY00018
F07RY00024
MANUAL SHIFTING TEST
NOTE:
With this test, it can be determined whether the trouble lies
within the electrical circuit or is a mechanical problem in
the transmission.
1. Disconnect TCM connector
With the engine OFF, disconnect the TCM connector.
2. Inspect manual driving operation
Check that the shift and gear positions correspond with the
table below.
If the "L", "2" and "D" range gear positions are difficult to
distinguish, do perform the following road test.
While driving, shift through the "L", "2" and "D" ranges.
Check that the gear change corresponds to the gear
position.
If any abnormality is found in the above test, do perform the
stall, time lag or gear change tests.
3. Connect TCM connector
With the engine off, connect the TCM connector.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–177
TRANSMISSION CASE
DISASSEMBLY
249RY00001
Disassembly steps
1. Spacer
2. Pin
3. Manual valve lever shaft
4. Manual valve lever
5. Oil seal
6. Oil seal

7A–178 AUTOMATIC TRANSMISSION (AW30-40LE)
249RY00002
249RY00003
249RY00004
240RY00021
Important operations
1. Spacer
Using a chisel, cut off the spacer and remover it from the
shaft.
2. Pin
Using a punch, drive out the pin.
3. Manual valve lever shaft
4. Manual valve lever
Pull the manual valve lever shaft out through the case by
the threads.
5. Oil seal
6. Oil seal
Using a screwdriver, remove the oil seal.
On–vehicle replacement of oil seal
Using special tool, install the oil seal.
Installer : 5–8840–2169–0 (J–37232–2)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–179
REASSEMBLY
249RX00001
Reassembly steps
1. Oil seal
2. Oil seal
3. Spacer
4. Manual valve lever
5. Manual valve lever shaft
6. Pin

7A–180 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00021
249RY00005
249RY00006
249RY00003
Important operations
1. Oil seal
2. Oil seal
Coat a new oil seal lip with multi purpose grease.
Using special tool, drive in the oil seal.
Oil seal installer : 5–8840–2169–0 (J–37232–2)
3. Spacer
4. Manual valve lever
Assemble a new spacer to the manual valve lever.
5. Manual valve lever shaft
Install the manual valve lever shaft to the transmission case
through the manual valve lever by the threads.
6. Pin
Drive in the pin with the slot at a right angle to the shaft.
Match the spacer hole to the lever staking hollow and stake
the spacer to the lever.
Make sure the manual valve lever shaft turns smoothly.

7A–202 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00017
244RY00017
249RY00011
249RY00012
4. Valve body
Align the groove of the manual valve to the pin of the lever.
Install the twenty bolts.
Each bolt length (mm) is indicated in the figure.
5. Solenoid wiring
Coat a new O–ring with ATF, and install it to the solenoid
wiring.
Insert the solenoid wiring to the case and install the stopper
plate.
Connect the connectors to the solenoid S1(1), S2(2), lock-
up solenoid (3), and pressure control solenoid (4).Nꞏm (kgꞏm/lbꞏin)
Torque 10 (1.0/87)

7A–206 AUTOMATIC TRANSMISSION (AW30-40LE)
249RW003
249RY00008
240RY00005
5. Elbow
Coat new O–rings with ATF, install them to the two elbows.
Install the elbows as shown in the figure.
6. Neutral start switch
Using the control shift lever, fully turn the manual lever shaft
back and return two notches. It is now in neutral.
Insert the neutral star t switch onto the manual valve shaft
and temporarily tighten the adjusting bolt.
Install the lock washer and install and torque the nut.
Align the neutral standard line and the switch groove and
tighten the adjusting bolt.
Bend the tabs of the lock washer.
NOTE:
Bend at least two of the lock washer tabs.
7. Control rod and shift lever
Install control shift lever.
11. Torque converter
Using calipers and a straight edge, measure from the
installed surface of the transmission housing.Nꞏm (kgꞏm/lbꞏft)
Torque 29 (3.0/22)
Nꞏm (kgꞏm/lbꞏin)
To r q u e 7 ( 0 . 7 / 6 1 )
Nꞏm (kgꞏm/lbꞏin)
Torque 13 (1.3/113)
Nꞏm (kgꞏm/lbꞏft)
Torque 29 (3.0/22)
mm (in.)
Correct distance 67(2.64) or more