OPEL FRONTERA 1998 Workshop Manual

7A–57 AUTOMATIC TRANSMISSION (4L30–E)
Converter Housing And Oil Pump Assembly
Disassembled View
241RW003
Legend
(1) Converter Housing
(2) Outer Seal Ring
(3) Gasket(4) Wear Plate
(5) Oil Pump Assembly
(6) Oil Seal Ring
Disassembly
1. Remove oil pump assembly from converter housing.
2. Remove outer seal ring.
3. Remove gasket.
4. Remove wear plate.
5. Remove oil seal ring.
Inspection And Repair
Visual Check:
If any damage, deformation, or local wear is found in a
converter housing, outer seal ring, wear plate, or oil seal
ring, replace it.
Reassembly
1. Install wear plate onto oil pump assembly.
2. Install converter housing onto complete oil pump
assembly. Align with two short 5–8840–2268–0
(J–38588) guide pins on outer bolt holes.
Loosely install five 13mm bolts.
Center converter housing using 5–8840–2272–0
(J–38557) centering tool.
Tighten five inner 13mm bolts in an alternating
pattern.
Torque: 20 N
m (2.0 kgꞏm/15 lb ft)
241RW020
3. Install oil seal ring (3 screws).
To r q u e : 3 N
m (0.3 kgꞏm/26 lb in)
4. Install gasket.
5. Install outer seal ring.

7A–58
AUTOMATIC TRANSMISSION (4L30–E)
Oil Pump
Disassembled View
241RS014
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–59 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–60
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.
Torque: 13 N
m (1.3 kgꞏm/113 lb in)
244RW004
Install gasket (transfer plate/main case).

7A–61 AUTOMATIC TRANSMISSION (4L30–E)
Adapter Case Valve Body
Disassembled View
243RW001
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
248RW001
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.
248RW006
7. Remove retaining washer (3), bearing (4), thrust
washer (5), and clutch plates (6 and 7) form the third
clutch drum assembly (8).

7A–64
AUTOMATIC TRANSMISSION (4L30–E)
Inspection And Repair
Visual Check:
If any damage, deformation or wear is found, replace the
damaged part.
Reassembly
1. Place third clutch drum and intermediate shaft
assembly upright, using the overdrive internal gear as
a support.
2. Install third clutch spring cushion plate (7), bevel face
down.
3. Install third clutch plates (6) into third clutch drum
assembly (8). Start with the steel clutch plate and
alternate with lined plates.
4. Install thrust washer (5), bearing (4), and retaining
washer (3).
5. Fully engage the hub splines of the input sun gear and
sprag unit assembly (2) into the third clutch inner
tangs.
Simultaneously rotate the outer sprag race to
engage into the third clutch drum assembly (8).
6. Place 5-8840-2258-0 (J-38450-A) blades between
the retaining ring and the third clutch drum
approximately (five) notches apart, and one blade at
each end of the retaining ring (1). Push down on sprag
assembly until the assembly is seated into the third
clutch drum assembly (8).
7. Remove the tool blades and engage retaining ring
into groove of third clutch drum.
248RW007

7A–65 AUTOMATIC TRANSMISSION (4L30–E)
Third Clutch
Disassembled View
248RS006
Legend
(1) Retaining Ring
(2) Spring Seat(3) Springs
(4) Piston Assembly
(5) Third Clutch Drum
Disassemble
1. Compress spring seat using the 5–8840–0501–0
(J–23075) spring compressor and 5–8840–2259–0
(J–23075–12) adapter tool.
NOTE: Do not over–stress the springs and seat. This will
cause damage to the spring seat.
Remove the tool.
Remove retaining ring (1).
248RW004
2. Release the spring seat (2).
NOTE: Do not let the spring seat catch in the ring groove.
Remove spring seat (2) and springs (3).
3. Remove piston assembly (4) from third clutch drum
(5).
Inspection And Repair
Visual check:
If any damage, deformation or wear is found, replace the
damaged part.
Operation check:
Shake the piston and listen for check ball movement
indicates proper check ball operation. Replace the piston
if the check ball is missing or falls out.
Reassembly
1. The lip of the piston seal must point toward the front of
the transmission. Lubricate the seal lip with
transmission fluid.
Install piston assembly (4) into the third clutch drum
(5). Use the 5–8840–2260–0 (J–23084) third clutch
piston installer to protect the outer seal during
installation.
Remove the seal installer.

7A–66
AUTOMATIC TRANSMISSION (4L30–E)
248RW005
2. Install twelve springs (3) and spring seat (2).
3. Place retaining ring (1) onto spring seat.
Compress the piston springs, using the
5–8840–0501–0 (J–23075) piston spring
compressor and 5–8840–2259–0 (J–23075–12)
adapter.
CAUTION: Do not over stress the springs and seat.
Do not let the spring seat catch in the ring groove.
This may cause damage to the spring seat.
Install spring seat retaining ring (1).
Remove the piston spring compressor and adapter.