brake OPEL FRONTERA 1998 Workshop Manual

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–21
TRANSMISSION DATA
Item Unit Enigne running at idle
Current Gear1
Lock Up Inactive, Active Inactive
Selector PositionPar k
AT Output Speed (Automatic Transmission) RPM 0 RPM
Output Speed (Meter Signal Side) RPM 0 RPM
AT Input Speed (Automatic Transmission) RPM 0 RPM
Engine Speed RPM 695
745 RPM
Vehicle Speed (Output Side) km/h 0 km/h
Throttle Position % 0 %
Throttle Position Sensor V 0.25
0.45V
AT Oil Temperature (Automatic Transmission)
C, F70 80C (158 176F)
Shift Pattern
Desired PCS Pressure (Pressure Control Solenoid) kPa
PCS Desired Current (Pressure Control Solenoid) mA
PCS Actual Current (Pressure Control Solenoid) mA
Overdrive Off Switch Off, On
Brake Switch Open 0V, Closed 12V Closed 12V
Winter Switch Open, Closed 0V Open
Power Switch Open, Closed 0V Open
Diagnostic Request Open, Closed Open
Winter Lamp Inactive 12V, Active 0V Inactive 12V
Power Lamp Inactive 12V, Active 0V Inactive 12V
Check Light Inactive 12V, Active 0V Inactive 12V
AT Oil Temperature Lamp (Automatic Transmission) Inactive 12V, Active 0V Inactive 12V
Solenoid 2-3 Inactive 0V, Active 12V Inactive 0V
Solenoid 1-2/3-4 Inactive 0V, Active 12V Active 12V
TCC Solenoid (Torque Conver ter Clutch) Inactive 0V, Active 12V Inactive 0V

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–63
F07RY00002
STALL TEST
The object of this test is to check the overall performance of the
transmission and engine by measuring the maximum engine
speeds at the "D" and "R" ranges.
NOTE:
(1) Perform the test at normal operation fluid temperature
(50 – 80
C or 122 – 176F).
(2) Do not continuously run this test longer than 5
seconds.
MEASURE STALL SPEED
1) Chock the four wheels.
2) Mount an engine tachometer.
3) Fully apply the parking brake.
4) Step down strongly on the brake pedal with your left foot.
5) Star t the engine.
6) Shift into the "D" range. Step all the way down on the
accelerator pedal with your right foot. Quickly read the
highest engine rpm.
7) Perform the same test in the "R" range.
EVALUATION
1) If the engine speed is the same for both ranges but lower
than the specified value:
• Engine output is insufficient.
• Stator one-way clutch is not operating properly.
NOTE:
If more than 600 rpm below the specified value, the torque
converter could be faulty.
2) If the stall speed in only "D" range is higher than specified:
• Line pressure too low
• Forward clutch slipping
• No. 2 one-way clutch not operating properly
3) If the stall speed in only "R" range is higher than specified:
• Line pressure too low
• Direct clutch slipping
• No. 3 brake slipping
4) If the stall speed in the "R" and "D" ranges are higher than
specified:
• Line pressure too low
• Improper fluid levelStall speed 2450
150rpm

7A–64 AUTOMATIC TRANSMISSION (AW30-40LE)
F07RY00003
TIME LAG TEST
If the shift lever is shifted while the engine is idling, there will be
a cer tain time elapse or lag before the shock can be felt. This is
used for checking the condition of the forward clutch, direct
clutch, No. 3 brake, and No. 2 one-way clutch.
NOTE:
(1) Perform the test at normal operation fluid temperature
(50 – 80
C or 122 – 176F).
(2) Be sure to allow one minute interval between tests.
(3) Make three measurements and take the average value.
MEASURE TIME LAG
1) Fully apply the parking brake.
2) Start the engine.
Check idling speed (A/C OFF)
3) Shift the shift lever from "N" to "D" range. Using a stop
watch, measure the time it takes from shifting the lever until
the shock is felt.
4) In same manner, measure the time lag for "N"
"R".
EVALUATION
1) If "N" "D" time lag is longer than specified:
• Line pressure too low
• Forward clutch malfunction
• No. 2 one-way clutch not operating properly
2) If "N"
"R" time lag is longer than specified:
• Line pressure too low
• Direct clutch malfunction
• No. 3 brake malfunction
3) If both time lag is longer than specified:
• Line pressure too low"N" range 695 – 745 rpm
Time lag Less than 0.7 seconds
Time lag Less than 1.2 seconds

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–65
F07RY00004
HYDRAULIC TEST
PREPARATION
1) Warm up the transmission fluid.
2) Remove the transmission case test plug and mount the
hydraulic pressure gauge.
Oil pressure gauge: 5-8840-0093-0
NOTE:
Perform the test at normal operating fluid temperature (50
– 80
C or 122 – 176F).
MEASURE LINE PRESSURE
1) Fully apply the parking brake and chock the four wheels.
2) Start the engine and check idling rpm.
3) Shift into "D" range, step down strongly on the brake pedal
with your left foot and, while manipulating the accelerator
pedal with the right foot, measure the line pressures at the
engine speeds specified in the table.
4) In the same manner, perform the test in "R" range.
EVALUATION
1) If the measured values at all ranges are higher than
specified.
• Pressure control solenoid defective.
• Primary regulator valve defective.
2) If the measured values at all ranges are lower than
specified.
• Primary regulator valve defective.
• Oil pump defective.
• Pressure control solenoid defective.
3) If pressure is low in "D" range only:
• "D" range circuit fluid leakage.
4) If pressure is low in "R" range only:
• "R" range circuit fluid leakage. Engine
speedLine pressure kPa (kg/cm
2/psi)
"D" range "R" range
Idling 358 – 417
(3.6–4.3 / 51–61)588 – 686
(6.0–7.0 / 85–100)
Stall 1,176 – 1,323
(12.0–13.5 / 171–192)1,607 – 1,940
(16.4–19.8 / 233–282)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–67
F07RY00007
F07RY00008
F07RY00009
F07RY00010
3) Run at "D" range lock-up or OD gear and check for
abnormal noise and vibration.
NOTE:
The check for the cause of abnormal noise and vibration
must be made with extreme care as it could also be due to
loss of balance in the propeller shaft, differential, the
torque converter, etc. or insufficient bending, rigidity, etc.
in the power train.
4) While running in "D" range, 2nd, 3rd gears and OD, check
to see that the possible kick-down vehicle speed limits for 2
1, 3 1, 3 2, OD 3 and OD 2 kick-downs
conform to those indicated on the automatic shift diagram.
5) Check for abnormal shock and slip at kick-down.
6) While running in "D" range, OD gear or "lock-up", shift to
"2" and "L" ranges and check the engine braking effect at
each of these ranges.
7) Also check to see that downshift is made from 3
2 or
from OD to 3 and then to 2 immediately and that 2
1
downshift point is within the limits shown in the diagram
when tested by releasing the accelerator pedal and shifting
into position of "L" while driving in the third gear or in
overdrive.
EVALUATION
(1) If there is no engine braking effect in the "2" range:
• Second coast (No. 1) brake is defective.
(2) If there is no engine braking effect in the "L" range:
• First and reverse (No. 3) brake is defective
(3) Also check to see that downshift is made from 3
2 or
from OD to 3 and then to 2 immediately and that 2
1
downshift point is within the limits shown in the diagram
when tested by releasing the accelerator pedal and shifting
into "L" position while driving in the third gear or in
overdrive.

7A–68 AUTOMATIC TRANSMISSION (AW30-40LE)
F07RY00011
F07RY00012
F07RY00020
F07RY00014
F07RY00015
"2" RANGE TEST
Shift into "2" range and, while driving with the accelerator pedal
held constantly at the specified point (throttle valve opening
50% and 100%), push in one of the pattern selectors (only for
4x4) and check on the following points.
1) At each of the above throttle openings, check to see that
the 1
2 up-shift takes place and that the shift points
conform to those shown on the automatic shift diagram.
NOTE:
There is no OD and no lock-up in the "2" range.
2) While running in the "2" range and 2nd gear, release the
accelerator pedal and check the engine's braking effect.
3) Check for 2
1 down-shift and abnormal noise at
acceleration and deceleration, and for shock at upshift and
down-shift.
"L" RANGE TEST
1) While running above 90 km/h (56 mph) in the "D" range,
release your foot from the accelerator pedal and shift into
the "L" range.
Then check to see that the 2
1 and 3 2 down-shift
occurs at the specified point shown on the automatic shift
diagram.
2) While running in the "L" range, check to see that there is no
up-shift to 2nd gear.
3) While running in the "L" range, release the accelerator
pedal and check the engine braking effect.
4) Check for abnormal noise during acceleration and
deceleration.
"R" RANGE TEST
Shift into the "R" range and, while starting at full throttle, check
for slipping.
"P" RANGE TEST
Stop the vehicle on a grade (more than 9%) and after shifting
into the "P" range, release the parking brake. Then check to
see that the parking lock pawl holds the vehicle in place.

7A–72 AUTOMATIC TRANSMISSION (AW30-40LE)
TCM STANDARD VOLTAGE
Check circuitTe r m i n a l
Measuring condition Voltage (V)
+-
Throttle position sensorC79-6 C79-28Throttle fully opened (WOT) 3.47
4.56
Throttle fully closed (idling) 0.25
0.45
C79-19 C79-18 Key switch ON 4.75
5.25
Output revolution sensor C79-4 C79-16 Engine idling in gear 0
3
Input revolution sensor C79-5 C79-17 Engine idling 0
3
Speed meter sensor C79-7C78-15
or -19Vehicle speed 10
20 km/h Less than 1.4
about 5
Brake switch C78-18C78-15
or -19Depress brake 7
16
Release brake Less than 1
O/D OFF switch C79-3C78-15
or -19O/D OFF switch ON (O/D OFF) 7
16
O/D OFF switch OFF (O/D ON) Less than 1
Neutral start switch
C79-2C78-15
or -19Selector “P” range 7
16
(P) Selector all ranges except “P” Less than 1
Neutral start switch
C79-1C78-15
or -19Selector “R” range 7
16
(R) Selector all ranges except “R” Less than 1
Neutral start switch
C79-9C78-15
or -19Selector “N” range 7
16
(N) Selector all ranges except “N” Less than 1
Neutral start switch
C79-8C78-15
or -19Selector “D” range 7
16
(D) Selector all ranges except “D” Less than 1
Neutral start switch
C79-21C78-15
or -19Selector “2” range 7
16
(2) Selector all ranges except “2” Less than 1
Neutral start switch
C79-20C78-15
or -19Selector “L” range 7
16
(L) Selector all ranges except “L” Less than 1
Engine revolution signal C79-15C78-15
or -19Engine idling Less than 1.4
9 16
Diagnosis terminal C79-24C78-15
or -19Self-diagnosis ON
0
1.5
Power pattern switch C79-23C78-15
or -19Power pattern switch OFF (NORMAL) 8
16
Power pattern switch ON (POWER) Less than 1.4
Winter select switch C79-13C78-15
or -19Switch OFF 8
16
Switch ON Less than 1.4
Electrical source (Battery) C78-13C78-15
or -19—
9
16
Electrical source (Ignition) C78-20C78-15
or -19Key switch ON
9
16
Oil temperature warning lamp C79-11C78-15
or -19Oil temperature warning lamp ON Less than 1
Oil temperature warning lamp OFF 8
16
“CHECK TRANS lamp” C79-10C78-15
or -19“CHECK TRANS” lamp ON Less than 1
“CHECK TRANS” lamp OFF 8
16
Power lamp C79-22C78-15
or -19Power lamp ON Less than 1
Powe r l a m p O F F 8
16

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–75
ON-VEHICLE SERVICE
242RX00001
TRANSIMISSION FLUID LEVEL AND
CONDITION
Park vehicle on level ground and set parking brake.
With the engine idling, move the shift lever through all
positions from "P" to "L", then return to position "P".
Check to see If the level of fluid comes to "HOT" range
of about 80
C (176F) on the dipstick gauge.
If the level of fluid is too low, replenish to bring it to
maximum level in "HOT" range.
Inspection of fluid condition
If the ATF is black or smells burnt, replace it.
ATF REPLACEMENT
NOTE:
Do not overfill.
1) Remove the drain plug from oil pan and drain the
fluid.
2) Reinstall the drain plug securely.
3) With the engine OFF, add new fluid through the filler
tube.
4) Star t the engine and shift the selector into all
position from "P" through "L", and then shift into "P".
5) With the engine idling, check the fluid level. Add fluid
up to the "COLD" level on the dipstick.
6) The ATF level must be checked again for correct
level with the "HOT" level.
NOTE:
To prevent fluid leaks, the drain plug gasket must be
replaced each time this plug is removed.
Tr a n s m i s s i o n
Drain and refill 5.2 L
Dry fill 8.7 L
Fluid BESCO ATF III

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–77
310RW020
F07RY00017
F07RY00018
BRAKE SIGNAL INSPECTION
Check that the brake light comes on when the brake pedal is
depressed.
VEHICLE SPEED SENSOR INSPECTION
1. Connect the Vehicle speed sensor connector terminal (1) to
the battery ( +) terminal and terminal (2) to the battery (-)
terminal.
2. Connect a resistance of 1.3k ohm to 5k ohm (1.4W or
more) between terminals (1) and (3).
NOTE:
Be extremely careful not to connect the battery (+) terminal
to the terminal (3)
This may damage the vehicle speed sensor.
3. Rotate the shaft of the vehicle speed sensor slowly and
measure the voltage at both ends with a digital tester.
Replace the sensor when the result of inspection is found
abnormal.
INPUT AND OUTPUT REVOLUTION
SENSOR INSPECTION
Use an ohmmeter to measure the resistance between
terminals 1 and 2.The voltage, with one rotation of shaft, fluctuates four
times in the following range: 10 to 14V
2V or less.
Standard resistance 560 – 680
(20C)
610 – 740
(40C)

7A–82 AUTOMATIC TRANSMISSION (AW30-40LE)
3) Make sure of proper operation of shift lock through checks
as follows:
a. Selector lever shall not be moved out of "P" position with
ingition key in "Lock" position.
b. Selector lever can be moved out of "P" position with
ignition key in "ON" position only when brake pedal is
depressed.
c. Ignition key can be turned to "LOCK" position only when
selector lever is in "P" position (key can be pulled out).
If (a) and (c) fail, readjust cable. If (b) fails, readjust
connector wiring and brake pedal switch.