clutch OPEL FRONTERA 1998 Workshop Manual

7A–188 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00014
248RY00019
248RY00020
247RY00012
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)

7A–190 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00021
248RY00022
248RY00023
247RY00015
13. E–ring and pin
Install the pin through the brake band.
Install the E–ring to the pin.
14. Bearing and race
Coat the bearing and race with petroleum jelly and install
them onto the forward clutch.
15. Race
Coat the race with petroleum jelly and install it onto the
front planetary ring gear. Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing 26.0 (1.024) 46.7 (1.839)
Race 26.0 (1.024) 48.9 (1.925)
Race diameter (Reference) mm (in.)
Inside Outside
Race 26.8 (1.055) 47.0 (1.850)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–191
247RY00016
247RY00017
247RY00019
247RY00018
Align the flukes of the discs in the forward clutch.
16. Front planetary ring gear
Align the spline of th front planetary gear with the flukes of
the discs and install the front planetary gear to the forward
clutch.
17. Bearing and race
Coat the bearing and race with petroleum jelly and install
them onto the ring gear.
18. Direct clutch and forward clutch
Install the assembled direct clutch, forward clutch and front
planetary ring gear into the transmission case. Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing 32.6 (1.283) 47.7 (1.878)
Race 30.6 (1.205) 53.6 (2.110)

7A–192 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00024
248RY00025
248RY00026
248RY00027
Using vernier calipers, measure the distance between the
sun gear input drum and direct clutch drum as shown in the
figure.
If the values are nonstandard, check for an improper
installation.
Coat the assembled bearing and race with petroleum jelly
and install it onto the forward clutch.
19. Second coast brake piston assembly
Coat the oil seal ring with ATF and install it to the second
coast brake piston.
Install the washer, spring and piston to the piston rod.
Install the E–ring.
(1): Second coast brake piston
(2): Oil seal
(3): Piston rod
20. Snap ring
Coat two new oil seals with ATF and install them to the
piston cover.
Install the spring, second coast brake piston assembly and
piston cover to the case.
Using snap ring pliers, install the snap ring.mm (in.)
Height9.8 – 11.8
(0.386 – 0.465)
Assembled bearing and race diameter (Reference)
mm (in.)
Inside Outside
Bearing
and race33.7 (1.327) 47.8 (1.882)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–197
252L100017
252L100001
252L100018
252RY00009
29. Race
Coat the race with petroleum jelly and install it onto the
planetary gear.
30.OD planetary gear and OD direct clutch
Install the overdrive planetary gear and direct clutch.
31.Bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the direct clutch.
Install the (flat ring) 4.0mm (0.157 in.) thick flange with the
rounded edge side of the flange facing the disc.
Alternately install three discs and two plates. (Disc first) Race diameter (Reference) mm (in.)
Inside Outside
Race 27.3 (1.075) 41.8 (1.646)
Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing and
race28.9 (1.138) 50.2 (1.976)

7A–198 AUTOMATIC TRANSMISSION (AW30-40LE)
246RY00001
252RY00014
241RY00003
Install the (stepped ring) flange with the flat side of the
flange facing the disc.
Install the snap ring.
32.Race
Coat the race with petroleum jelly and install it onto the oil
pump.
33.Oil pump
Coat the O–ring with ATF and install it around the pump
body.
Place the oil pump through the input shaft, and align the
bolt holes of the pump body with the transmission case.
Hold the input shaft, and lightly press the oil pump body to
slide the oil seal rings on the stator shaft through the direct
clutch drum.
NOTE:
Do not push on the oil pump strongly or the oil seal ring
will stick to the direct clutch drum.
Install the seven bolts.
Check input shaft rotation
Make sure the input shaft rotates smoothly. Race diameter (Reference) mm (in.)
Inside Outside
Race 28.1 (1.106) 47.3 (1.862)
Nꞏm(kgꞏm / lbꞏft)
Torque 22 (2.2/16)

7A–200 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00013
240RY00014
240RY00027
Important operations
1. Second brake drum gasket
Install a new brake drum gasket to the transmission case.
Individual piston operation inspection
Check for the sound of operation while injecting
compressed air into the oil hole indicated in the figure.
NOTE:
When inspecting the direct clutch, check with the C–0
accumulator piston hole closed. If there is no noise,
disassemble and check the condition of the parts.
A : C–0 Accumulator piston hole
2. Accumulator piston
Coat the O–ring with ATF and install it to the piston.
Install the five springs and four accumulator pistons to the
bore as shown in the figure. 1: OD direct clutch 5: Second coast brake
2: Direct clutch 6. Second brake
3: Forward clutch 7. First and reverse brake
4: OD brake

TRANSMISSION CONTROL SYSTEM (4L30–E)7A1–1
TRANSMISSION
TRANSMISSION CONTROL SYSTEM (4L30–E)
CONTENTS
Service Precaution 7A1–2. . . . . . . . . . . . . . . . . . . . . .
General Description 7A1–2. . . . . . . . . . . . . . . . . . . . .
Electronic Control Diagram 7A1–3. . . . . . . . . . . . .
Powertrain Control Module (PCM) 7A1–4. . . . . . .
Control System Diagram 7A1–5. . . . . . . . . . . . . . .
Shift Control 7A1–6. . . . . . . . . . . . . . . . . . . . . . . . . .
Band Apply Control 7A1–6. . . . . . . . . . . . . . . . . . . .
Torque Converter Clutch Control 7A1–6. . . . . . . . .
Line Pressure Control 7A1–6. . . . . . . . . . . . . . . . . .
On–Board Diagnostic System 7A1–6. . . . . . . . . . .
Fail Safe Mechanism 7A1–6. . . . . . . . . . . . . . . . . . .
Torque Management Control 7A1–6. . . . . . . . . . . .
ATF Warning Control 7A1–6. . . . . . . . . . . . . . . . . . .
ABS Control (If equipped) 7A1–6. . . . . . . . . . . . . .
Shift Mode Control 7A1–7. . . . . . . . . . . . . . . . . . . . .
Gear Shift Control 7A1–8. . . . . . . . . . . . . . . . . . . . .
Winter Drive Mode 7A1–9. . . . . . . . . . . . . . . . . . . . .
Backup Mode 7A1–9. . . . . . . . . . . . . . . . . . . . . . . . .
Functions of Input / Output Components 7A1–10. .
Diagnosis 7A1–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Diagnosis 7A1–11. . . . . . . . . . . . . . . . . . .
Check Trans Indicator 7A1–11. . . . . . . . . . . . . . . . . .
Diagnostic Check 7A1–11. . . . . . . . . . . . . . . . . . . . . .
“Check Trans” Check 7A1–12. . . . . . . . . . . . . . . . . .
Tech2 OBD II Connection 7A1–13. . . . . . . . . . . . . . .
F0: Transmission Data 7A1–18. . . . . . . . . . . . . . . . .
F1: PC Solenoid Data 7A1–19. . . . . . . . . . . . . . . . . .
OBD II Diagnostic Management System 7A1–20. .
16 – Terminal Data Link Connector (DLC) 7A1–21.
Malfunction Indicator Lamp (MIL) 7A1–22. . . . . . . .
Types Of Diagnostic Trouble Codes (DTCs) 7A1–22
Clear DTC 7A1–22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC Check 7A1–23. . . . . . . . . . . . . . . . . . . . . . . . . . .
PCM Precaution 7A1–23. . . . . . . . . . . . . . . . . . . . . . .
Information On PCM 7A1–23. . . . . . . . . . . . . . . . . . .
Intermittent Conditions 7A1–23. . . . . . . . . . . . . . . . . Transmission And PCM Identification 7A1–24. . . . .
Isuzu Trooper 7A1–25. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Identification 7A1–26. . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0218 Transmission Fluid Over
Temperature 7A1–27. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0560 System Voltage Malfunction 7A1–29. . .
DTC P0705 Transmission Range Switch
(Mode Switch) Illegal Position 7A1–32. . . . . . . . . . . .
DTC P0706 Transmission Range Switch
(Mode Switch) Performance 7A1–35. . . . . . . . . . . . . .
DTC P0712 Transmission Fluid Temperature
(TFT) Sensor Circuit Low Input 7A1–38. . . . . . . . . . .
DTC P0713 Transmission Fluid Temperature
(TFT) Sensor Circuit High Input 7A1–41. . . . . . . . . . .
DTC P0719 TCC Brake Switch Circuit High
(Stuck On) 7A1–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0722 Transmission Output Speed
Sensor (OSS) Low Input 7A1–47
. . . . . . . . . . . . . . . . .
DTC P0723 Transmission Output Speed
Sensor (OSS) Intermittent 7A1–50. . . . . . . . . . . . . . .
DTC P0730 Transmission Incorrect Gear
Ratio 7A1–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0748 Pressure Control Solenoid
(PCS) (Force Motor) Circuit Electrical 7A1–56. . . . .
DTC P0753 Shift Solenoid A Electrical 7A1–58. . . . .
DTC P0758 Shift Solenoid B Electrical 7A1–61. . . . .
DTC P1790 ROM Transmission Side Bad
Check Sum 7A1–65. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1792 EEPROM Transmission Side
Bad Check Sum 7A1–66. . . . . . . . . . . . . . . . . . . . . . . .
DTC P1835 Kickdown Switch Always On 7A1–67. . .
DTC P1850 Brake Band Apply Solenoid
Malfunction 7A1–69. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1860 TCC Solenoid Electrical 7A1–73. . . . . . .
Transmission Fluid Temperature (TFT)
Sensor Specifications 7A1–76. . . . . . . . . . . . . . . . . . .

7A1–2
TRANSMISSION CONTROL SYSTEM (4L30–E)
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
General Description
The 4L30–E is a 4–speed fully automatic transmission. It
uses a microcomputer as a control unit to judge running
conditions including throttle opening rate and vehicle
speed, then it sets the shifting point in the optimum timing
so that best driving performance can be achieved.
In addition, the built–in shift mode select function can
select three shift modes according to the driver’s
preference:
Normal mode –Normal shift pattern.
Winter mode –Starts in 3rd gear to reduce slippage on
ice or snow.
Power mode has a delayed upshift for when more
powerful acceleration is required.
Also, the built–in fail safe function (“backup mode”)
assures driving performance even if the vehicle speed
sensor, throttle signal or any solenoid fails.
Further, the self–diagnostic function conducts diagnosis
in a short time when the control system fails, thus
improving serviceability.
The major features of 4L30–E are as follows:
A compact structure consisting of 2 sets of planetary
gears and flat torque converter.
Electronic control selects the optimum shift mode
according to the driving conditions.
Electronic control maintains the optimum hydraulic
pressure for clutch, band brake as well as
transmission so that shift feeling is improved.
Two sets of planetary gears reduce friction of power
train.
Also, a lockup mechanism in the torque converter
reduces fuel consumption.
Wide gear ratio and high torque rate of torque
converter provide excellent starting performance.

7A1–6
TRANSMISSION CONTROL SYSTEM (4L30–E)
Shift Control
The transmission gear is shifted according to the shift
pattern selected by the driver. In shifting gears, the gear
ratio is controlled by the ON/ OFF signal using the shift
solenoid A and the shift solenoid B.
Band Apply Control
The band apply is controlled when in the 3–2 downshift
(engine overrun prevention) and the garage shift (shock
control).
The band apply solenoid is controlled by the signal from
the Pulse Width Modulation (PWM) to regulate the flow of
the oil.
Torque Converter Clutch Control
The clutch ON/OFF is controlled by moving the converter
clutch valve through shifting Torque Converter Clutch
(TCC) solenoid using the ON/OFF signal.
Line Pressure Control
The throttle signal allows the current signal to be sent to
the force motor. After receiving the current signal, the
force motor activates the pressure regulator valve to
regulate the line pressure.
On–Board Diagnostic System
Several malfunction displays can be stored in the
Powertrain Control Module (PCM) memory, and read out
of it afterward.The serial data lines, which are required for the testing of
the final assembly and the coupling to other electronic
modules, can be regulated by this function.
Fail Safe Mechanism
If there is a problem in the transmission system, the PCM
will go into a “backup” mode.
The vehicle can still be driven, but the driver must use the
select lever to shift gears.
Torque Management Control
The transmission control side sends the absolute spark
advance signal to the engine control side while the
transmission is being shifted. This controls the engine
spark timing in compliance with the vehicle running
condition to reduce the shocks caused by the change of
speed.
ATF Warning Control
The oil temperature sensor detects the ATF oil
temperature to control the oil temperature warning, TCC,
and the winter mode.
ABS Control (If equipped)
When the select lever is at “L” or “R” range, a signal is sent
to the ABS controller as one of the ABS control
conditions.