clutch OPEL FRONTERA 1998 Workshop Manual

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–145
REASSEMBLY
248RY00064
Reassembly steps
1. Thrust bearing
2. Oil seal ring
3. O-ring
4. O-ring
5. Forward clutch piston
6. Piston retur n spring
7. Snap ring
8. Cushion plate
9. Disc and plate
10. Flange
11. Snap ring
12. Race
13. Thrust bearing

7A–146 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00044
248RY00046
248RY00047
248RY00049
Important operations
1. Thrust bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the forward clutch drum, with the race
side facing downward.
2. Oil seal ring
Coat the three oil rings with ATF.
Contract the oil seal rings as shown, and install three oil
seal rings onto the forward clutch drum.
NOTE:
Do not spread the ring ends more than necessary.
3. O-ring
Coat a new O-ring with ATF and install O-ring on the
forward clutch drum.
4. O-ring
Coat new O-rings with ATF and install two O-rings on the
forward clutch piston.
5. Forward clutch piston
Being careful not to damage the O-rings, press the forward
clutch piston into the forward clutch drum. Assembled bearing and race (Reference) mm (in.)
Inside diameter 33.7 (1.327)
Outside diameter 47.8 (1.882)

7A–148 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00041
248RY00040
248RY00048
11. Snap ring
Install the snap ring with a screw driver. Be sure the end
gap of the snap ring is not aligned with the cutout por tion of
the forward clutch drum.
Check piston stroke of forward clutch (C–1)
Using a dial indicator, measure the forward clutch piston
stroke by applying and releasing the compressed air (4–
8kg/cm
2, 57–114psi or 392–785kPa) as shown.
If the Pack clearance is not within specification, select
another flange, and recheck the piston stroke.
There are eight flanges.
12. Race
13. Thrust bearing
Coat the race and bearing with petroleum jelly, and install
them onto the forward clutch drum. mm(in.)
Pack clearance0.6–1.0
(0.0236–0.0394)
mm (in.)
No. Flange thickness No. Flange thickness
61 3.0 (0.118) 92 3.4 (0.134)
63 4.2 (0.165) 93 3.6 (0.142)
64 4.4 (0.173) 94 3.8 (0.150)
91 3.2 (0.126) 95 4.0 (0.158)
Race and bearing diameter (Reference) mm(in.)
Inside Outside
Race 26.0 (1.024) 48.9 (1.925)
Bearing 26.0 (1.024) 46.7 (1.839)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–149
248RY00039
248RY00038
Install direct clutch assembly to forward clutch assembly
Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward clutch
assembly.
Check that distance from the direct clutch end to the forward
clutch end is 71.2 mm (2.803 in.).
mm (in.)
71.2 (2.803)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–153
PLANETARY SUN GEAR AND NO.1 ONE–WAY CLUTCH
DISASSEMBLY
248RY00050
Disassembly steps
1. One–way clutch and second brake hub
2. Thrust washer (Plastic)
3. Oil seal ring (Metal)
4. Snap ring
5. Snap ring

7A–154 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00051
248RY00052
248RY00053
248RY00054
Important operations
Check operation of No.1 one–way clutch
Hold the planetary sun gear and turn the second brake
hub. The second brake hub should turn freely clockwise
and should lock counterclockwise.
(1) : Free
(2) : Lock
3. Oil seal ring (Metal)
Remove two oil seal rings.
4. Snap ring
Remove the snap ring with snap ring pliers.
INSPECTION AND REPAIR
Check planetary sun gear bushing
Using a dial indicator, measure the inside diameter of the
planetary sun gear bushing.
If the inside diameter is greater than the maximum, replace
the planetary sun gear.mm (in.)
Maximum inside diameter 27.08 (1.0661)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–155
REASSEMBLY
248RY00066
Reassembly steps
1. Snap ring
2. Sun gear input drum
3. Snap ring
4. Oil seal ring (Metal)
5. Thrust washer (Plastic)
6. One–way clutch and second brake hub

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–157
248RY00057
248RY00058
248RY00051
5. Thrust washer (plastic)
Install thrust washer.
NOTE:
Make sure that the lugs fit into the holes on the sun gear
input drum.
6. One–way clutch and second brake hub
Install assembled No.1 one–way clutch and second brake
hub onto planetary sun gear as shown.
Check operation of No.1 one–way clutch
Hold the planetary sun gear and turn the second brake
hub. The second brake hub should turn freely clockwise
and should lock counterclockwise.
(1) : Free
(2) : Lock

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–163
REAR PLANETARY GEAR ASSEMBLY AND OUTPUT SHAFT
DISASSEMBLY
247RY00027
Disassembly steps
1. Second brake assembly
2. Output shaft
3. Oil seal ring
4. Disc, plate and flange
5. Rear planetary gear assembly
6. One–way clutch inner race
7. Snap ring

8. One–way clutch
9. Thrust washer (Plastic)
10. Thrust washer (Plastic)
11. Thrust bearing and race
12. Snap ring
13. Ring gear flange

7A–164 AUTOMATIC TRANSMISSION (AW30-40LE)
247RY00028
247RY00029
247RY00030
247RY00031
Important operations
3. Oil seal ring
Remove oil seal ring from output shaft.
5. Rear planetary gear assembly
Remove rear planetary gear from rear planetary ring gear.
Check operation of No.2 one–way clutch
Hold the planetary gear and turn the one–way clutch inner
race. The one–way clutch inner race should turn freely
counterclockwise and should lock clockwise.
(1) : Lock
(2) : Free
6. One–way clutch inner race
Remove the one–way clutch inner race from the rear
planetary gear.