OPEL FRONTERA 1998 Workshop Manual

7A–130 AUTOMATIC TRANSMISSION (AW30-40LE)
252RY00047
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Important operations
1. Oil seal ring
Coat the two oil seal rings with ATF.
Contract the oil seals as shown, and install them onto the
OD support.
NOTE:
Do not spread the ring ends more than necessary.
2. O-ring
Coat two new O-rings with ATF and install them on the OD
brake piston.
3. OD brake piston
Being careful not to damage the O-rings, press in the brake
piston into the OD suppor t, using both hands.
4. Piston return spring
Install piston return spring.
5. 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)
Install the snap ring with a screwdriver. Be sure the end gap
of the snap ring is not aligned with cutout portion of the OD
support.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–131
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6. Thrust washer (plastic)
Coat the thrust washer with petroleum jelly and install it onto
the OD support.
NOTE:
Make sure that the lug fits into the hole on the OD support.
7. Race
Coat the race with petroleum jelly, and install it onto the OD
support.
8. Thrust bearing
Turn over OD suppor t.
Coat the two races with petroleum jelly, and install them
onto the OD support. Race diameter (Reference) mm (in.)
Inside diameter 36.8 (1.449)
Outside diameter 50.9 (2.004)
Race and bearing diameter (Reference) mm (in.)
Inside Outside
Race (A) 37.2 (1.465) 58.8 (2.315)
Bearing 36.5 (1.437) 48.5 (1.910)
Race (B) 33.7 (1.327) 50.1 (1.973)

7A–132 AUTOMATIC TRANSMISSION (AW30-40LE)
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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.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–133
DIRECT CLUTCH ASSEMBLY (C-2)
DISASSEMBLY
248RY00059
Disassembly steps
1. Clutch drum thrust washer
2. Snap ring
3. Flange
4. Plate and disc
5. Snap ring
6. Piston return spring
7. Direct clutch piston
8. O-ring

7A–134 AUTOMATIC TRANSMISSION (AW30-40LE)
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Important operations
Remove direct clutch drum assembly from forward clutch
assembly.
Check piston stroke of direct clutch (C-2)
Place the direct clutch assembly onto the OD suppor t
assembly.
Using a dial indicator, measure the direct clutch piston
stroke by applying and releasing compressed air (4– 8 kg/
cm
2, 57– 114 psi or 392– 785 kPa) as shown.
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: 5-8840-0254-0 (J-25048)mm (in.)
Piston stroke1.6– 1.9
(0.0630– 0.0748)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–135
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7. Direct clutch piston
Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply compressed
air to the OD support to remove the direct clutch piston.
Remove the direct clutch piston.
Remove two O-ring from piston.
INSPECTION AND REPAIR
Check piston return spring
Using calipers, measure the free length of the return spring.
Check discs
Using a micrometer, measure the thickness of the discs.
If the thickness is less than the minimum, replace the disc.
Check 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.)
Standard 21.3 (0.839)
mm (in.)
Minimum thickness 1.84 (0.0724)

7A–136 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00032
Check direct clutch drum bushing
Using a dial indicator, measure the inside diameter of the
clutch drum bushing.
If the inside diameter is grater than maximum, replace the
clutch drum.mm (in.)
Maximum inside diameter 53.99 (2.1256)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–137
REASSEMBLY
248RY00060
Reassembly steps
1. O-ring
2. Direct clutch piston
3. Piston retur n spring
4. Snap ring
5. Disc and plate
6. Flange
7. Snap ring.
8. Clutch drum thrust washer (plastic)

7A–138 AUTOMATIC TRANSMISSION (AW30-40LE)
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Important operations
1. O-ring
Coat new O-rings with ATF and install them on the direct
clutch piston.
2. Direct clutch piston
Install direct clutch piston to direct clutch drum.
Being careful not to damage the O-rings, press in the direct
clutch piston into the clutch drum, using both hands.
3. Piston return spring
Install piston return spring.
4. Snap ring
Compress piston return spring and install snap ring in
groove.
Place special tool and a suitable ring on the spring retainer,
and compress the return spring.
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.
Spring compressor: 5-8840-0254-0 (J-25048)
5. Disc and plate
Install plates and discs.
Install in order: P– D– P– D– P– D– P– D– P– D
P: Plate, D: Disc

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–139
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6. Flange
Install the flange, with the flat side facing downward.
7. Snap ring
Install the snap ring with a screwdriver. Be sure the end
gap of the snap ring is not aligned with the cutout portion of
the direct clutch drum.
Check piston stroke of direct clutch (C-2)
Place the direct clutch assembly onto the OD suppor t
assembly.
Using a dial indicator, measure the direct clutch piston
stroke by applying and releasing 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
discs and recheck the piston stroke.
If the piston stroke is non standard, select another flange.
There are eight flanges.mm (in.)
Piston stroke1.6– 1.9
(0.0630– 0.0748)
mm (in.)
No. Flange thickness No. Flange thickness
33 3.3 (0.130) 37 3.7 (0.146)
34 3.4 (0.134) 38 3.8 (0.150)
35 3.5 (0.138) 39 3.9 (0.154)
36 3.6 (0.142) 40 4.0 (0.158)