OPEL FRONTERA 1998 Workshop Manual

7A–67 AUTOMATIC TRANSMISSION (4L30–E)
Sprag Unit
Disassembled View
248RS009
Legend
(1) Retaining Ring
(2) Sprag Outer Race
(3) Ring(4) Sprag Assembly
(5) Ring
(6) Third Clutch Hub and Sun Gear Assembly
Disassembly
1. Remove the sprag outer race, retaining ring, and
sprag assembly from the third clutch hub and sun
gear assembly.
2. Remove the rings and sprag assembly from the sprag
outer race.
Inspection And Repair
Visual Check:
If any damage, deformation or wear is found, replace the
damaged part.
Reassembly
NOTE: Flared shoulder of the sprag cage faces the sun
gear. This procedure must be followed exactly to be sure
that the sprag assembly is installed properly.
1. Install rings and sprag assembly onto the third clutch
hub and sun gear.
2. Install sprag outer race and retaining ring assembly
over the sprag cage assembly.
Place third clutch hub and sun gear assembly on a
flat surface, sun gear facing up. Place sprag outer
race and sprag assembly over the sun gear
assembly, push down and turn the input sun
counterclockwise at the same time. NOTE: Check correct rotation by holding the sun gear in
your left hand and turning the outer race. The outer sprag
race should turn freely towards you and should lock
turning away from you.
248RS010

7A–68
AUTOMATIC TRANSMISSION (4L30–E)
Second Clutch
Disassembled View
247RW001
Legend
(1) Retaining Ring
(2) Ring Gear
(3) Retaining Ring
(4) Spacer
(5) Clutch Plates(6) Waved Washer
(7) Retaining Ring
(8) Spring Seat
(9) Springs
(10) Piston Assembly
(11) Second Clutch Drum
Disassembly
1. Remove retaining ring (1) from second clutch drum
(11).
2. Remove ring gear (2), retaining ring (3), and spacer
(4).
3. Remove clutch plates (5) and waved washer (6).
4. Remove retaining ring (7) using 5–8840–0195–0
(J–23327) compressor to compress the spring seat
(8).
5. Remove spring seat (8), springs (9) and piston
assembly (10) from second clutch drum (11).
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7A–69 AUTOMATIC TRANSMISSION (4L30–E)
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.
Movement indicates proper check ball operation.
Replace the piston if the check ball is missing or falls out.
Reassembly
1. Install piston assembly (10) into the second clutch
drum (11).
Lubricate the lip seal with transmission fluid. Use
the 5–8840–2261–0 (J–23080–A) second clutch
piston installer to protect the outer piston lip seal.
NOTE: Lip of the seal should point toward front of
transmission.
Remove the installer.
247RS007
2. Install twenty–two piston springs (9) and spring seat
(8) on the second clutch piston (10). Place retaining
ring (7) onto spring seat.
Use the 5–8840–0195–0 (J–23327) compressor to
compress the piston springs.
NOTE: Do not let spring seat catch in ring groove.
Remove the compressor.3. Install waved plate (6) and clutch plates (5). Start with
a steel plate and alternate with lined plates.
Align second clutch inner tangs.
4. Install spacer (4), with the fluted end toward clutch
plates.
5. Install retaining ring (3), ring gear (2) and retaining
ring (1).

7A–70
AUTOMATIC TRANSMISSION (4L30–E)
3–4 Accumulator Piston
Disassembled View
244RS005
Legend
(1) Snap Ring
(2) Cover(3) Spring
(4) Piston Assembly
Disassembly
1. Install the 5–8840–2277–1 (J–38559–A) cover
compressor on adapter case.
Compress piston cover then remove snap ring.
242RW009
2. Install the 5–8840–2403–0 (J–41096) cover remover
and 5–8840–2266–0 (J–38584) adapter to center
hole of cover.
Use the 5–8840–0019–0 and 5–8840–2000–0
(J–23907) slide hammer to remove cover.
3. Remove spring and piston assembly.
242RW010
Inspection And Repair
Visual Check:
If any damage, deformation or wear is found, replace the
damaged part.

7A–71 AUTOMATIC TRANSMISSION (4L30–E)
Reassembly
1. Place the 5–8840–2264–0 (J–38553) piston fitter into
adaptor case and push the piston into position, using
suitable diameter tube.
Remove the piston fitter.
244RW005
2. Install spring and cover.
3. Install snap ring, using the 5–8840–2277–1
(J–38559–A) compressor tool.
Install snap ring in groove.
Remove the compressor tool.
244RW006

7A–72
AUTOMATIC TRANSMISSION (4L30–E)
Reverse Clutch Piston And Center Support
Disassembled View
242RS006
Legend
(1) Retaining Ring
(2) Spring Seat
(3) Springs
(4) Piston Assembly
(5) Center Support
(6) Gasket(7) Transfer Plate
(8) Gasket
(9) Restrictor
(10) Retainer Plate
(11) Plug
(12) Spring
(13) Overrun Lock Out Valve
Disassembly
1. Install the 5–8840–0195–0 (J–23327) compressor
tool on spring seat, then compress the spring seat.
Remove retaining ring (1).
NOTE: Do not over–stress the springs and seat, as this
will cause damage to the spring seat.
Remove the compressor tool.

7A–73 AUTOMATIC TRANSMISSION (4L30–E)
247RW006
2. Remove spring seat (2) and springs (3).
3. Remove piston assembly (4).
4. Remove 8 bolts from center support (5), then remove
center support (5) from adapter case.
5. Remove gasket transfer plate/outer support (6),
center support transfer plate (7), and gasket transfer
plate/adapter case (8).
6. Remove restrictor (9) from adapter case housing.
7. Remove retainer plate (10), plug (11), spring (12), and
overrun lock out valve (13) from center support (5).
Inspection And Repair
Visual Check:
If any damage, deformation or wear is found, replace the
damaged part.
Reassembly
1. Install overrun lock out valve (13) and spring (12) to
center support.
NOTE: Ensure correct assembly of valve. The spring
should be located over the long small diameter end.
2. Install plug (11) and retainer plate (10).
3. Place restrictor (9) in the lube overdrive channel in the
adapter case housing.
242RS005
4. Install gasket transfer plate/adapter case (8), center
support transfer plate (7), and gasket transfer
plate/center support (6).
5. Install center support (5) with 8 bolts.
Torque : 25 N
m (2.5 kgꞏm/18 lb ft)
6. Install piston assembly (4) into center support (5).
7. Install twenty four springs (3), spring seat (2), and
retaining ring (1).
Install the 5–8840–0195–0 (J–23327) compressor
and compress spring seat (2) and springs (3), then
seat snap ring (1) in groove.
Remove the tool.

7A–74
AUTOMATIC TRANSMISSION (4L30–E)
Overrun Clutch And Turbine Shaft
Disassembled View
252RW005
Legend
(1) Snap Ring
(2) Overdrive Carrier Assembly
(3) Sun Gear
(4) Turbine Shaft
(5) Snap Ring
(6) Backing Plate
(7) Clutch Plates(8) Snap Ring
(9) Overrun Roller Clutch Cam
(10) Roller Clutch Assembly
(11) Overrun Clutch Release Spring Retainer
(12) Diaphragm Spring
(13) Piston Assembly
(14) Overrun Clutch Drum
(15) Turbine Shaft Seal Rings
Disassembly
1. Position overrun clutch assembly upright, using the
overdrive internal gear as a support.
Remove snap ring (1).

7A–75 AUTOMATIC TRANSMISSION (4L30–E)
252RS009
2. Remove overdrive carrier assembly (2), sun gear (3)
and turbine shaft (4).
3. Remove snap ring (5), backing plate (6), and clutch
plates (7).
4. Compress diaphragm spring with the
5–8840–2275–0 (J–23327–91) compressor, then
remove snap ring (8).
252RW011
5 . R e m o v e o v e r r u n r o l l e r c l u t c h c a m ( 9 ) a n d r o l l e r c l u t c h
assembly (10).
6. Remove overrun clutch release spring retainer (11)
and diaphragm spring (12).
7. Remove piston assembly (13) from overrun clutch
drum (14).
8. Remove turbine shaft seal rings (15).
Inspection And Repair
Overdrive Carrier Check
Check pinion end play with a feeler gauge.
Clearance: 0.24mm–0.64mm (0.0094in–0.025in)
If clearance is outside specified value, replace overdrive
carrier assembly.
252RS011
Visual Check:
If any damage, deformation or local wear is found,
replace the damaged part.
Reassembly
1. Install turbine shaft seal rings (15) with grease
(petroleum jelly).
241RS008

7A–76
AUTOMATIC TRANSMISSION (4L30–E)
2. Install the 5–8840–2269–0 (J–38555) inner installer
on the drum (14).
Pre–install piston assembly into 5–8840–2269–0
(J–38555) outer installer.
Install overrun clutch piston assembly (13). Use the
outer installer while pushing piston into drum (14).
Remove the installer.
252RW012
252RW013
3. Install diaphragm spring (12).
4. Install overrun clutch release spring retainer (11) (lip
faces upwards), overrun roller clutch assembly (10),
and cam (9).
5. Place snap ring loosely on spring retainer.
Hold the 5–8840–2275–0 (J–23327–91)
compressor in a vise and compress piston return
spring with compressor.
Set snap ring (8) in ring groove.
Remove the compressor.
6. Install clutch plates (7), start with steel plate and
alternate with lined plates.
7. Install backing plate (6). 8. Install snap ring (5).
9. Install overdrive sun gear with countersink pointing
downwards.
10. Install the overdrive carrier assembly (2).
NOTE: Tu r n t h e a s s e m b l y i n a c o u n t e r – c l o c k w i s e
direction only until roller clutch enters the outer race.
After installation, rotate the assembly and listen for loose
rollers.
11. Install turbine shaft (4) and snap ring (1).