OPEL FRONTERA 1998 Workshop Manual

7A–120 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY
252L100010
Reassembly steps
1. Thrust washer
2. OD one-way clutch
3. Retaining plate
4. Snap ring
5. Race
6. Ring gear flange
7. Snap ring
8. Thrust bearing
9. O-ring
10. OD direct clutch piston with O-ring
11. Piston return spring
12. Snap ring
13. Flange, disc and plate
14. Snap ring
15. Thrust bearing
16. OD direct clutch assembly

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–121
252RY00032
252RY00033
252RY00026
252RY00024
Important operations
1. Thrust washer
Install the thrust washer to the OD planetary gear, facing
the grooved side upward.
2. OD one-way clutch
Install the one-way clutch into the outer race, with the
flanged side of the one-way clutch facing upward.
Install OD one-way clutch with outer race to overdrive
planetary gear.
3. Retaining plate
4. Snap ring
Install retaining plate, then install snap ring, using a
screwdriver.

7A–122 AUTOMATIC TRANSMISSION (AW30-40LE)
252RY00034
252RY00023
252RY00022
252RY00035
5. Race
Coat the race with petroleum jelly and install it to the
planetary gear.
6. Ring gear flange
Install ring gear flange to OD planetary ring gear.
7. Snap ring
Install snap ring, using a screwdriver.
8. Thrust bearing
Coat the race and bearing with petroleum jelly and install
them onto the OD planetary ring gear. Race diameter (Reference) mm (in.)
Inside diameter 27.3 (1.075)
Outside diameter 41.8 (1.646)
Race and bearing diameter (Reference) mm (in.)
Inside Outside
Race 24.2 (0.953) 47.8 (1.882)
Bearing 26.0 (1.024) 46.8 (1.843)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–123
252L100011
252L100012
252L100007
252L100013
9. O-ring
Coat new O-rings with ATF and install them on the OD
direct clutch piston.
10. OD direct clutch piston with O-ring
Being careful not to damage the O-rings, press in the OD
direct clutch piston into the clutch drum, using both hands.
11. Piston return spring
Install piston return spring.
12. Snap ring
Place special tool and a suitable ring on the spring retainer,
and compress the return spring.
Spring compressor: 5-8840-0195-0 (J-23327-1)
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.
13. Flange, disc and plate
Install two plates and two discs then install the flange, with
the flat side facing downward.

7A–124 AUTOMATIC TRANSMISSION (AW30-40LE)
252L100014
252L100005
252L100016
14. Snap ring
Install snap ring.
Check piston stroke of OD direct clutch (C-0).
Place the oil pump onto the torque converter, and then
place the OD direct clutch assembly onto the oil pump.
Using a dial indicator, measure the OD direct clutch piston
stroke by applying and releasing the compressed air (4– 8
kg/cm
2, 57– 114 psi or 392– 785 kPa) as shown.
If the piston stroke is not within specification, replace the
disc and recheck the piston stroke.
If the piston stroke is non standard, select another flange.
There are six flange sizes.mm (in.)
Piston stroke mm (in.)1.85– 2.15
(0.0728– 0.0847)
mm (in.)
No. Flange thickness No. Flange thickness
16 3.6 (0.142) 19 3.3 (0.130)
17 3.5 (0.138) 20 3.2 (0.126)
18 3.4 (0.134) 21 3.1 (0.122)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–125
252L100015
252L100004
252L100003
15. Thrust bearing
Coat the assembled bearing and race with petroleum jelly
and install it with the race side facing downward.
16. OD direct clutch assembly
Align the flukes of discs in the direct clutch .
Install the OD direct clutch assembly onto the OD planetary
gear.
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 Assembled bearing and race (Reference) mm (in.)
Inside diameter 28.9 (1.138)
Outside diameter 50.2 (1.976)

7A–126 AUTOMATIC TRANSMISSION (AW30-40LE)
OD SUPPORT ASSEMBLY
DISASSEMBLY
252RY00041
Disassembly steps
1. Thrust bearing
2. Race
3. Thrust washer (plastic)
4. Snap ring
5. Piston return spring
6. OD brake piston
7. O-ring

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–127
252RY00042
252RY00043
252RY00044
252RY00045
Important operations
Check OD brake piston
Place the OD suppor t assembly onto the direct clutch
assembly.
Apply compressed air into the oil passage as shown, and be
sure that the OD brake piston moves smoothly.
4. Snap ring
Place special tool on the spring retainer, and compress the
return spring with a shop press.
Spring compressor: 5-8840-2170-0 (J-37233)
Remove the snap ring with a screwdriver.
6. OD brake piston
Place the OD suppor t onto the direct clutch assembly.
Hold the OD brake piston so it is not slanted and apply
compressed air into the passage to remove the OD brake
piston.
Remove the OD brake piston.

7A–128 AUTOMATIC TRANSMISSION (AW30-40LE)
252RY00046
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
Check piston return spring
Using calipers, measure the free length of the return spring.
mm (in.)
Standard 17.2 (0.677)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–129
REASSEMBLY
252RY00068
Reassembly steps
1. Oil seal ring
2. O-ring
3. OD brake piston
4. Piston retur n spring
5. Snap ring
6. Thrust washer (Plastic)
7. Race
8. Thrust bearing