OPEL FRONTERA 1998 Workshop Manual

7A–100 AUTOMATIC TRANSMISSION (AW30-40LE)
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7. Flange, plate and disc
Remove two flanges, three plates and four discs.
8. Bearing and race
Remove the thrust bearing and two races.
9. Snap ring
Using snap ring pliers, remove the snap ring.
10. OD support
Remove two bolts fixing the overdrive suppor t assembly to
the case.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–101
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Install two removed bolts to the OD support, and pull out
the OD suppor t assembly.
11. Race
Remove two races from OD suppor t.
Check piston stroke of second coast brake
Place a mark on the second coast brake piston rod as shown in
the figure.
Using feeler gauge, measure the stroke applying the
compressed air (4 – 8kg/cm
2
, 57 – 114psi or 392 – 785 kPa) as
shown in the figure.
mm (in.)
If the values are nonstandard, replace piston rod and
recheck piston stroke. If piston stroke is nonstandard,
replace brake band.
There are two piston rods.Piston stroke 1.5–3.0 (0.059-0.118)
Rod length71.4mm (2.811 in.)
72.9mm (2.870 in.)

7A–102 AUTOMATIC TRANSMISSION (AW30-40LE)
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12. Snap ring
Using snap ring pliers, remove the snap ring.
13. Second coast brake piston assembly
Applying compressed air to the oil hole, remove the second
coast brake piston assembly.
14. Direct clutch and forward clutch
Remove the direct clutch and forward clutch from the case.
15. E-ring and pin
Remove the E-ring from the pin.
Remove the pin from the brake band.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–103
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16. Second coast brake band
Remove the second coast brake band from the case.
17. Front planetary ring gear
Remove the front planetary ring gear from the case.
18. Bearing and race
Remove the bearing and race.
19. Race
Remove the race.

7A–104 AUTOMATIC TRANSMISSION (AW30-40LE)
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20. Snap ring
Using snap ring pliers, remove the snap ring.
21. Front planetary gear
Remove the front planetary gear from the case.
22. Drum and one-way clutch
Remove sun gear input drum and one-way clutch.
Check pack clearance of second brake
Using a feeler gauge, measure the clearance between the
snap ring and flange as shown in the figure.
If the values are nonstandard, replace the discs.mm (in.)
Clearance0.62–1.98
(0.0244–0.0780)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–105
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23. Snap ring
Using two screwdrivers, remove the snap ring.
24. Flange, plate and disc
Remove the flange, five discs and five plates.
Check pack clearance of first and reverse brake
Using a feeler gauge, measure the clearance between the
plate and second brake drum as shown in the figure.
If the values are nonstandard, select another flange.
25. Snap ring
Using snap ring pliers, remove the snap ring.mm (in.)
Clearance0.7–1.0
(0.0276–0.0394)
Available flange sizes mm (in.)
4.0 (0.158) 4.8 (0.189)
4.2 (0.165) 5.0 (0.197)
4.4 (0.173) 5.2 (0.205)
4.6 (0.181) 5.4 (0.213)

7A–106 AUTOMATIC TRANSMISSION (AW30-40LE)
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26. Rear planetary gear, second brake drum and output
shaft
Remove the rear planetary gear, second brake drum and
output shaft as an assembly.
27. Bearing
Remove the assembled thrust bearing and race from the
case.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–107
DISASSEMBLY, INSPECTION AND
REASSEMBLY OF MINOR COMPONENTS
The instructions here are organized so that you work on only
one component group at a time.
This will help avoid confusion from similar-looking parts of
different subassemblies being on your workbench at the same
time.
The component groups are inspected and repaired from the
converter housing side.
As much as possible, complete the inspection, repair and
reassembly before proceeding to the next component group. If
a component group cannot be reassembled because parts are
being ordered, be sure to keep all parts of that group in a
separate container while proceeding with disassembly,
inspection, repair and reassembly of other component groups.
Recommended ATF type BESCO ATF II or III.
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean and any
fluid passages and holes blown through with compressed
air.
2. When using compressed air to dry parts, always aim away
from yourself to prevent accidentally spraying automatic
transmission fluid in your face.
3. The recommended automatic transmission fluid should be
used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the par ts should be arranged in proper order
to allow performing inspection, repairs, and reassembly
with efficiency.
2. When disassembling a valve body, be sure to keep each
valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid for at
least thir ty before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts,
and sliding surfaces should be coated with transmission
fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that ends of a snap ring are not aligned with one
of the cutouts and are installed in the groove correctly.
4. If a worn bushing is to be replaced, the subassembly
containing that bushing must be replaced.
5.Check thrust bearings and races for wear or damage.
Replace if necessary.
6. Use petroleum jelly or vaseline to keep par ts in place.

7A–108 AUTOMATIC TRANSMISSION (AW30-40LE)
OIL PUMP
DISASSEMBLY
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Important operations
1. Oil seal ring
Use torque converter as work stand.
Remove 2 oil seal rings from stator shaft.
2. O-ring
Remove O-ring.
Disassembly steps
1. Oil seal ring
2. O-ring
3. Stator shaft 4. Oil pump drive gear
5. Oil pump driven gear

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–109
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3. Stator shaft
Remove 13 bolts, and then remove the stator shaft from oil
pump body.
Then remove drive and driven gear.
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
Check oil pump body bushing
Using a dial indicator, measure the inside diameter of the
oil pump body bushing.
If the inside diameter is greater than the maximum, replace
the oil pump body.
Check stator shaft bushing
Using a dial indicator, measure the inside diameter of the stator
shaft bushing.
If the inside diameter is greater than maximum, replace the
stator shaft.mm (in.)
Maximum inside diameter 38.19 (1.5035)
mm (in.)
Maximum inside
diameterFront side 21.58 (0.8496)
Rear side 27.08 (1.0661)