brake OPEL FRONTERA 1998 Workshop Manual

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–173
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6. Reaction sleeve
Insert special tool behind the reaction sleeve and gradually
lift it out of the transmission case.
Reaction sleeve puller : 5–8840–2173–0 (J–37236)
8. 1st and reverse brake piston No.1
Insert special tool behind the No.1 brake piston and
gradually lift it out of the transmission case.
Piston puller : 5–8840–2174–0 (J–37237)

7A–174 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY
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Reassembly steps
1. O–ring
2. O–ring
3. 1st and reverse brake piston No.1
4. O–ring
5. Reaction sleeve
6. 1st and reverse brake piston No.2
7. Return spring
8. Snap ring
9. Thrust bearing and race

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–175
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Important operations
1. O–ring
Coat three new O–rings with ATF.
Install the two O–ring on the No.1 piston.
2. O–ring
Install the O–ring on the reaction sleeve.
3. 1st and reverse brake piston No.1
Install the No.1 piston to the reaction sleeve.
4. O–ring
Coat a new O–ring with ATF and install it on the No.2
piston.
5. Reaction sleeve
Install the No.1 piston with reaction sleeve onto the No.2
piston.
6. 1st reverse brake piston No.2
Align the teeth of the No.2 piston into the proper grooves.
Being careful not to damage the O–rings, press in the No.2
with No.1 first and reverse brake pistons into the
transmission case.
7. Return spring
Place piston return spring onto No.2 piston.

7A–176 AUTOMATIC TRANSMISSION (AW30-40LE)
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8. Snap ring
Set special tool as shown, and compress the return spring
with special tool.
Spring compressor : 5–8840–0254–0 (J–25048)
Install the snap ring with snap ring pliers. Be sure the end
gap of the snap ring is not aligned with the spring retainer
claw.
Check first and reverse brake piston
Make sure the first and reverse brake piston moves
smoothly when applying and releasing the compressed air
into the transmission case.
9. Thrust bearing and race
Coat the assembled bearing and race with petroleum jelly.
Install the assembled bearing and race facing the bearing
side upward.
Assembled bearing and race
diameter. (Reference) mm (in.)
Inside diameter 39.2 (1.543)
Outside diameter 57.7 (2.272)

7A–182 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY OF MAJOR COMPONENTS
Disassembly, inspection and reassembly of each
component group have been indicated in the preceding
chapter. Before reassembly, make sure, again, that all
component groups are assembled correctly.
If something wrong is found in a certain component group
during assembly, inspect and repair this group immediately.
GENERAL ASSEMBLY NOTES:
1. The automatic transmission is composed of highly
precision–finished parts, necessitating careful inspection
before assembly because even a small nick could cause
fluid leakage or affect performance.
2. Before assembling new clutch discs and brake bands, soak
them in automatic transmission fluid for at least thir ty
minutes.
3. Apply automatic transmission fluid on the sliding or rotating
surfaces of parts before assembly.
4. Use petroleum jelly to keep small par ts in their places.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new
gaskets and O–rings.
7. Dry all par ts with compressed air - never use shop rags.
8.Be sure to install the thrust bearings and races in the
correct direction and position.

7A–184 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY OF MAJOR COMPONENTS (1)
248L100002
Reassembly steps
1. Bearing
2. Rear planetary gear, second brake drum
and output shaft
3. Snap ring
4. Second brake piston sleeve
5. One–way clutch
6. Flange plate and disc
7. Snap ring
8. Drum
9. Front planetary gear and bearing
10. Snap ring
11. Race
12. Second coast brake band
13. E–ring and pin
14. Bearing and race
15. Race
16. Front planetary ring gear
17. Bearing and race
18. Direct clutch and forward clutch
19. Second coast brake piston assembly
20. Snap ring
21. Race

7A–186 AUTOMATIC TRANSMISSION (AW30-40LE)
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Important operations
1. Bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the case.
2. Rear planetary gear, second brake drum and output
shaft
Align the teeth of the second brake drum, flanges, discs
and plates as shown in the figure.
Align the splines of the transmission case and the
assembled rear planetary gear, second brake drum and
output shaft, indicated by A in the figure at left.
3. Snap ring
Using snap ring pliers, install the snap ring. Assemble bearing and race (reference) mm (in.)
Bearing and race Diameter
Inside 39.2 (1.543)
Outside 57.7 (2.272)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–187
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Check pack clearance of first and reverse brake
Using a thickness gauge, measure the clearance between
the plate and second brake drum as shown in the figure.
If the values are nonstandard, check for an improper
installation.
4. Second brake piston sleeve
Install second brake piston sleeve.
5. One–way clutch
Install one–way clutch.
6. Flange plate and disc
Install flange, discs and plates.
Install the 2.5mm (0.098in.) thick plate with the rounded
edge side of the plate facing the disc.
Alternately install four discs and three plates (Disc first)
Install the flange with the rounded edge of the flange facing
the disc.mm (in.)
Clearance 0.7–1.0
(0.0276–0.0394)

7A–188 AUTOMATIC TRANSMISSION (AW30-40LE)
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7. Snap ring
Install the snap ring.
Check pack clearance of second brake
Using a thickness gauge, measure the clearance between
the snap ring and flange as shown in the figure.
If the values are nonstandard, check for an improper
installation.
8. Drum
While turning the sun gear input drum clockwise, install it
into the one-way clutch.
NOTE:
Confirm the thrust washers are installed correctly.
9. Front planetary gear and bearing
Install the front planetary gear to the sun gear.
NOTE:
Confirm the bearing and race is installed correctly.mm (in.)
Clearance0.62–1.98
(0.0244–0.0780)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–189
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With wooden blocks under the output shaft, stand the
transmission on the output shaft.
10. Snap ring
Using snap ring pliers, install the snap ring.
11. Race
Coat the bearing race with petroleum jelly and install it onto
the front planetary gear.
12. Second coast brake band
Insert the second coast brake band to the case. Bearing race diameter (Reference) mm (in.)
Bearing race Diameter
Inside 34.3 (1.350)
Outside 47.8 (1.882)