automatic transmission OPEL FRONTERA 1998 Workshop 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

7A–2 AUTOMATIC TRANSMISSION (AW30-40LE)
VALVE BODY ASSEMBLY AND PRESSERE CONTOROL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . 7A–84
TRANSMISSION REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–86
UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–91
DISASSEMBLY OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–91
DISASSEMBLY, INSPECTION AND REASSEMBLY OF MINOR COMPONENTS. . . . . . . . . . . . . . . . . 7A–107
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–108
OD PLANETARY GEAR AND OD DIRECT CLUTCH ASSEMBLY (C-0) . . . . . . . . . . . . . . . . . . . . . . . . 7A–114
OD SUPPORT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–126
DIRECT CLUTCH ASSEMBLY (C-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–133
FORWARD CLUTCH ASSEMBLY (C-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–141
FRONT PLANETARY GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–150
PLANETARY SUN GEAR AND NO.1 ONE–WAY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–153
SECOND BRAKE ASSEMBLY (B–2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–158
REAR PLANETARY GEAR ASSEMBLY AND OUTPUT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–163
FIRST AND REVERSE BRAKE (B–3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–171
TRANSMISSION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–177
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–181
REASSEMBLY OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–182
MAIN DATA AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–207
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–207
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–208
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–211
CAUTION: When fasteners are removed, always
reinstall them at a the same location from which
they were removed. If a fastener needs to be
replaced, use the correct part number fastener for
that application. If the correct part number fastener
is not available, a fastener of equal size and
strength (or stronger) may be used. Fasteners that
are not reused, and those requiring thread locking
compound, will be called out. The correct torque
values must be used when installing fasteners that
require torque. If the above conditions are not
followed, parts or system damage could result.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–3
GENERAL DESCRIPTION
CONSTRUCTION
A07RY00001

7A–4 AUTOMATIC TRANSMISSION (AW30-40LE)
ELECTRONIC CONTROL COMPONENTS
C07RY00072

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–5
TRANSMISSION CONTROL MODULE (TCM)
C07RY00027

7A–6 AUTOMATIC TRANSMISSION (AW30-40LE)
CONTROL SYSTEM DIAGRAM
C07RY00071

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–7
CONTROL AND FUNCTIONS
Item Description
Shift and lock-up control • In D range, speed change point and Lock-up point can be changed by
setting pattern selection switch to "POWER", "NORMAL" or "WINTER"
mode.
• Gear shift position in the conditions made up of transmission shift positions
(D.2.L) combined with pattern selection switch (POWER, NORMAL, and
WINTER) can be controlled in accordance with vehicle speed and the
opening of throttle valve.
Overdrive cut control • If O/D OFF switch is set on in D range (O/D OFF lamp ON), gear shift to O/
D is not effected.
• Overdrive is released at O/D OFF switch on and high transmission oil
temperature (More than 130
C).
However, to prevent engine over revolution
•4
3 shifting at vehicle speed is less than 118 km/h.
•3
4 shifting at vehicle speed is more than 131 km/h.
Lock-up cut control • In D range, 3rd or O/D lock-up is conducted in "POWER" or "NORMAL"
mode.
• In 2, L range, lock-up is off in the whole area.
• Lock-up timing is controlled to reduce gear shift shock using kind of gear
shift (shift up, etc.) lock-up status at the time of gear shift judgement, gear
step and throttle opening after gear shift.
• Lock-up is released at brake on or high transmission oil temperature (More
than 130
C).
• Lock-up is prohibited when idling is defected by throttle position sensor.
Driving mode select control • The TCM selects a suitable driving mode from the nine kinds for the variety
driving condition.
i) Economy mode ii) Power mode iii) Winter mode iv) HOT1 mode v) HOT2
mode vi) L4 mode vii) Slope mode (Up slope 1, Up slope 2 and Down
slope mode)
• The priority of driving mode:
Economy < Power < Slope < L4 < Winter < HOT1 < HOT2
Squat control • When the TCM detects D signal on, the TCM controls 1–3–1 shift by
setting a timer, in order to improve the shift feel at N
D.
Line pressure control • The TCM output current which corresponds to throttle oil pressure to
pressure control solenoid based on throttle opening.
Indicate oil temperature warning
function• If the transmission oil temperature sensor senses that transmission oil
temperature is greater than 146
C, the TCM turn on A/T OIL TEMP
warning lamp. (The warning lamp is turned off, if oil temperature is less
than 126
C.)
L4 mode control • The TCM judges whether the transfer is engaged in high or low based on
the ratio rpm data from output speed sensor in the transmission and the
rpm data from speed meter sensor to select the shift map.
Up and down hill control • The TCM judges up and down hill, and change shift pattern based on
throttle opening and acceleration.
Correct oil temperature control • If the temperature exceeds a predetermined value, the TCM selects the
high oil temperature shift point for downshifting, thus preventing the oil
temperature from rising. (More than 130
C, D range)

7A–8 AUTOMATIC TRANSMISSION (AW30-40LE)
Winter mode control • The TCM controls the vehicle start smoothly on low frictional road like
snow road by executing this control.
Activate condition:
1. Excluding "2", "L" range
2. Vehicle speed is less than 11 km/h
3. Transmission oil temperature is less than 115
C
4. Throttle opening is less than 8%
5. Excluding winter mode
Cancel condition:
1. When winter mode switch is pushed again
2. When either "2" or "L" is detected
3. Ignition switch "OFF"
4. Vehicle speed is more than 34 km/h for 1 second or mode continuously
5. Transmission oil temperature is more than 130
C
Fail-safe function • When trouble occurs to vehicle sensor and each solenoid, TCM
automatically exer ts fail-safe control not to spoil driveability.
• This control is exer ted when sensor or actuator is in trouble, while TCM
works normally.
Diagnosis function • If there is an abnormality in vehicle sensors, each solenoid (S1-S3, STH),
or throttle position sensor, "CHECK TRANS" lamp is actuated to warn the
drive. But when the abnormality items have been restored to normal, the
light does not blink.
• Faulty parts are memorized in TCM. If self-diagnosis star t signal is
inputted, "CHECK TRANS" lamp is blinked and results of diagnosis are
indicated. A history of faults remains recorded even when IGN switch is off.
TECH 2 • Output of control data in the TCM
• Actuator (Solenoid) operation check
• Erasure of trouble code

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–9
MAJOR INPUT/OUTPUT COMPONENTS
Component Function
Input
Vehicle speed sensor (Speedometer) Detects the vehicle speed (Back-up sensor of output
revolution sensor).
Output revolution sensor (Transmission) Detects the vehicle speed.
Input revolution sensor (Transmission) Detects the input revolution (O/D direct clutch drum
revolution).
Engine revolution sensor Detects the engine revolution.
Throttle position sensor Detects the throttle opening rate.
Neutral start switch Detects the select lever position.
Pattern select switch Detects whether the driver has selected "NORMAL",
"POWER", or "WINTER" mode.
Overdrive off switch Detects whether the driver has selected O/D.
Brake lamp switch Detects whether the driver has pressed the brake pedal or
not.
Oil temperature sensor Detects the oil temperature.
Diagnostic star t switch Star ts self-diagnosis and displays a code for faulty part if
any.
Input/Output
Data link connector When connected with Tech2 or tester, can communicate
the data for function check, etc.
Output
Shift solenoid S1, S2 Selects shift point and gear position suited to the vehicle
running condition on the basis of TCM output.
Lock-up control solenoid SL Control the lock-up clutch suited to the vehicle running
condition on the basis of TCM output.
Pressure control solenoid STH Adjusts throttle pressure by energizing current of linear
pressure control solenoid to prevent the shift shock and to
obtain shift smoothly.
"CHECK TRANS" lamp When trouble has occurred to throttle position sensor,
vehicle speed sensor, or solenoid, "CHECK TRANS" lamp
is blinked to warn the driver. If also displays the trouble
code.
A/T OIL TEMP warning lamp Lights when ATF oil temperature rises. (Turned on at
greater than 146
C . Turned off at less than 126C.
Power mode lamp Informs the driver whether the vehicle is in power mode or
not.
Winter mode lamp Informs the driver whether the vehicle is in winter mode or
not.
Computer
Transmission Control Module (TCM) Based on the signal from each switch and sensors, judges
necessary shift point and lock-up operation, and send
signal to each solenoid.

7A–10 AUTOMATIC TRANSMISSION (AW30-40LE)
LOCATION OF CLUTCH, BRAKE, ONE-WAY CLUTCH AND SOLENOID
C07RY00006
EndOFCallout
Legend
C-0: Overdrive direct clutch
C-1: Forward clutch
C-2: Direct clutch
B-0: Overdrive brake
B-1: Second coast brake
B-2: Second brake
B-3: First and reverse brake
F-0: Overdrive one-way clutch
F-1: One-way clutch (No.1)
F-2: One-way clutch (No.2)
S-1: Shift solenoid S1
S-2: Shift solenoid S2
S-3: Lock-up solenoid SL
S-4: Pressure control solenoid STH