OPEL FRONTERA 1998 Workshop Manual

7A–110 AUTOMATIC TRANSMISSION (AW30-40LE)
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Check tip clearance of both gears
Measure between the gear teeth and the cresent-shaped
par t of the pump body.
If the tip clearance is greater than the maximum, replace
the drive gear, driven gear or pump body.
Check body clearance of driven gear
Push the driven gear to one side of the body.
Use a feeler gauge, measure the clearance.
If the body clearance is greater than the maximum, replace
the drive gear, driven gear or pump body.
Check side clearance of both gears
Using a steel straightedge and a feeler gauge, measure the
side clearance of both gears.
If the side clearance is greater than the maximum, replace
the drive gear, driven gear or pump body.
Check oil seal
Check for wear, damage or cracks.
If necessary, replace oil seal.
Pry off the oil seal with a screwdriver.mm (in.)
Standard tip clearance0.11–0.14
(0.0043–0.0055)
Maximum tip clearance 0.3 (0.012)
mm (in.)
Standard body clearance0.07–0.15
(0.0028–0.0059)
Maximum body clearance 0.3 (0.012)
mm (in.)
Standard side clearance0.02–0.05
(0.0008–0.0020)
Maximum side clearance 0.1 (0.004)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–111
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Using special tool, install a new oil seal.
The oil seal end should be flush with the outer edge of the
pump body.
Oil seal installer: 5-8840-2256-0 (J-9617)
Coat the oil seal lip with multi purpose grease.

7A–112 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY
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Important operations
1. Oil pump driven gear
Place the oil pump body on the torque converter.
Coat the driven gear and drive gear with ATF.
Install the driven gear and drive gear.
Reassembly steps
1. Oil pump driven gear
2. Oil pump drive gear
3. Stator shaft
4. Oil seal ring
5. O-ring

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–113
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3. Stator shaft
Align the stator shaft with the bolt holes.
Tighten the thir teen bolts.
4. Oil seal ring
Coat the oil seal rings with ATF.
Contract the oil seal rings as shown, and install them onto
the stator shaft.
NOTE:
Do not spread the ring ends too much.
5. O-ring
Coat a new O-ring with ATF and install it to the oil pump
body.
Check oil pump drive gear rotation
Make sure the drive gear rotates smoothly when installed to
the torque converter.Nꞏm (kgꞏm/Ib in)
Torque 11 (1.1/95)
O-ring size (Reference) mm (in.)
Inside diameter 204.9 (8.067)
Thickness 3.5 (0.138)

7A–114 AUTOMATIC TRANSMISSION (AW30-40LE)
OD PLANETARY GEAR AND OD DIRECT CLUTCH ASSEMBLY (C-0)
DISASSEMBLY
252L100002
Disassembly steps
1. OD direct clutch assembly
2. Thrust bearing
3. Snap ring
4. Flange, disc and plate
5. Snap ring
6. Piston retur n spring
7. OD direct clutch piston with O-ring
8. O-ring
9. Thrust bearing
10. Snap ring
11. Ring gear flange
12. Race
13. Snap ring
14. Retaining plate
15. OD one-way clutch
16. Thrust washer

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–115
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Important operations
Check operation of one-way clutch
Hold the OD direct clutch drum and turn the input shaft.
The input shaft should turn freely clockwise and should lock
counterclockwise.
(1): Free
(2): Lock
1. OD direct clutch assembly
Remove OD direct clutch assembly from OD planetary
gear.
2. Thrust bearing
Then remove thrust bearing with the race from OD direct
clutch drum.
Check piston stroke of OD direct clutch (C-O)
Place the oil pump onto the torque conver ter, and then
place the OD direct clutch assembly onto the oil pump.
Use a dial indicator, measure the OD direct clutch piston
stroke applying and releasing the compressed air (4– 8 kg/
cm
2, 57– 114 psi, 392– 785 kPa) as shown.
mm (in.)
Piston stroke1.85– 2.15
(0.0728– 0.0847)

7A–116 AUTOMATIC TRANSMISSION (AW30-40LE)
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3. Snap ring
Remove snap ring from clutch drum.
4. Flange, disc and plate
Remove flange, two discs and two plates.
5. Snap ring
Place special tool and a suitable ring on the spring retainer
and compress the return spring. Using snap ring pliers,
remove the snap ring.
Spring compressor: 5-8840-0195-0 (J-23327-1)
6. Piston return spring
Remove piston return spring.
7. OD direct clutch piston with O-ring
Place the oil pump onto the torque converter and then
place the OD direct clutch onto the oil pump.
Holding the OD direct clutch piston by hand, apply
compressed air to the oil pump to remove the OD direct
clutch piston.
Remove the OD direct clutch piston.
8. O-ring
Remove two O-rings from piston.
9. Thrust bearing
Remove bearing and race from OD planetary ring gear.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–117
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10. Snap ring
Remove snap ring.
11. Ring gear flange
Remove ring flange from OD planetary ring gear.
13. Snap ring
Remove snap ring, using screwdriver.
14. Retaining plate
Remove retaining plate from OD planetary gear.

7A–118 AUTOMATIC TRANSMISSION (AW30-40LE)
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15. OD one-way clutch
Remove OD one-way clutch with outer race.
INSPECTION AND REPAIR
Check discs
Using a micrometer, measure the thickness of the discs.
If the thickness is less than the minimum, replace the disc.
Check piston return spring
Using calipers, measure the free length of the return spring.
Check OD direct clutch piston
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying low-pressure
compressed air.mm (in.)
Minimum thickness 1.84 (0.0724)
mm (in.)
Standard length 15.8 (0.622)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–119
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Check OD direct clutch drum bushings
Using a dial indicator, measure the inside diameter of the
clutch drum bushings.
If the inside diameter is greater than the maximum, replace
the clutch drum.
Check OD planetary gear bushing
Using a dial indicator, measure the inside diameter of the
planetary gear bushing.
If the inside diameter is greater than the maximum, replace
the planetary gear.mm (in.)
Maximum inside diameter 27.11 (1.0673)
mm (in.)
Maximum inside diameter 11.27 (0.4437)