OPEL FRONTERA 1998 Workshop Manual

7A–140 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00037
248RY00038
8. Clutch drum thrust washer (plastic)
Coat the thrust washer with petroleum jelly and install it onto
the direct clutch.
NOTE:
Make sure that the lugs fit into the cutout portions on the
direct clutch.
Install direct clutch assembly
Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward clutch
assembly.
Check that the distance from the direct clutch end to the
forward clutch end is 71.2 mm (2.803 in.).

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–141
FORWARD CLUTCH ASSEMBLY (C-1)
DISASSEMBLY
248RY00063
Disassembly steps
1. Thrust bearing
2. Race
3. Snap ring
4. Flange
5. Disc and plate
6. Snap ring
7. Piston return spring
8. Piston
9. O-ring
10. O-ring
11. Oil seal ring
12. Thrust bearing

7A–142 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00039
248RY00048
248RY00040
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Important operations
Remove forward clutch assembly from direct clutch
assembly.
1. Thrust bearing
Place wooden blocks, etc, to prevent forward clutch shaft
from touching the work stand, and place the OD suppor t on
them.
Place the forward clutch onto the OD support and remove
the bearing and race.
Check piston stroke of forward clutch (C–1)
Using a dial indicator, measure the forward clutch piston
stroke by applying and releasing compressed air (4–8kg/
cm
2, 57–114psi or 392–785kPa)as shown.
3. Snap ring
Remove snap ring from clutch drum.mm (in.)
Pack clearance 0.6–1.0 (0.0236–0.0394)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–143
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6. Snap ring
Place special tool 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)
8. Piston
PLace the forward clutch drum onto the OD support.
Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the forward
clutch piton.
INSPECTION AND REPAIR
Check forward 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.
Check forward clutch drum bushing
Using a dial indicator, measure the inside diameter of the
forward clutch drum bushing.
If the inside diameter is greater than the maximum, replace
the forward clutch drum.mm (in.)
Maximum inside diameter 24.08 (0.948)

7A–144 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00045
247RY00034
Check disc, plate and flange
Check to see if the sliding surface of the disc, plate and
flange are worn or burnt. If necessary, replace them.
• If the lining of the disc is peeling off or discolored, or even
if par ts of the printed numbers are defaced, replace all
discs.
• Before assembling new discs, soak them in ATF for at
least fifteen minutes.
Check piston return spring
Using calipers, measure the free length of the return spring.
mm (in.)
Standard length 19.47 (0.7665)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–145
REASSEMBLY
248RY00064
Reassembly steps
1. Thrust bearing
2. Oil seal ring
3. O-ring
4. O-ring
5. Forward clutch piston
6. Piston retur n spring
7. Snap ring
8. Cushion plate
9. Disc and plate
10. Flange
11. Snap ring
12. Race
13. Thrust bearing

7A–146 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00044
248RY00046
248RY00047
248RY00049
Important operations
1. Thrust bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the forward clutch drum, with the race
side facing downward.
2. Oil seal ring
Coat the three oil rings with ATF.
Contract the oil seal rings as shown, and install three oil
seal rings onto the forward clutch drum.
NOTE:
Do not spread the ring ends more than necessary.
3. O-ring
Coat a new O-ring with ATF and install O-ring on the
forward clutch drum.
4. O-ring
Coat new O-rings with ATF and install two O-rings on the
forward clutch piston.
5. Forward clutch piston
Being careful not to damage the O-rings, press the forward
clutch piston into the forward clutch drum. Assembled bearing and race (Reference) mm (in.)
Inside diameter 33.7 (1.327)
Outside diameter 47.8 (1.882)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–147
248RY00065
248RY00003
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6. Piston return spring
Install piston return spring.
7. Snap ring
Place special tool on the spring retainer, and compress the
return spring.
Spring compressor: 5–8840–0254–0 (J–25048)
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.
8. Cushion plate
Install cushion plate rounded side down as shown.
9. Disc and plate
Install discs. plates and flange.
Install in order:P–D–P–D–P–D–P–D–P–D–P–D
10. Flange
And then install the flange, with the rounded edge facing
downward.

7A–148 AUTOMATIC TRANSMISSION (AW30-40LE)
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248RY00040
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11. Snap ring
Install the snap ring with a screw driver. Be sure the end
gap of the snap ring is not aligned with the cutout por tion of
the forward clutch drum.
Check piston stroke of forward clutch (C–1)
Using a dial indicator, measure the forward clutch piston
stroke by applying and releasing the compressed air (4–
8kg/cm
2, 57–114psi or 392–785kPa) as shown.
If the Pack clearance is not within specification, select
another flange, and recheck the piston stroke.
There are eight flanges.
12. Race
13. Thrust bearing
Coat the race and bearing with petroleum jelly, and install
them onto the forward clutch drum. mm(in.)
Pack clearance0.6–1.0
(0.0236–0.0394)
mm (in.)
No. Flange thickness No. Flange thickness
61 3.0 (0.118) 92 3.4 (0.134)
63 4.2 (0.165) 93 3.6 (0.142)
64 4.4 (0.173) 94 3.8 (0.150)
91 3.2 (0.126) 95 4.0 (0.158)
Race and bearing diameter (Reference) mm(in.)
Inside Outside
Race 26.0 (1.024) 48.9 (1.925)
Bearing 26.0 (1.024) 46.7 (1.839)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–149
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Install direct clutch assembly to forward clutch assembly
Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward clutch
assembly.
Check that distance from the direct clutch end to the forward
clutch end is 71.2 mm (2.803 in.).
mm (in.)
71.2 (2.803)