OPEL FRONTERA 1998 Workshop Manual

7A–160 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY
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Reassembly steps
1. O–ring
2. Second brake piston
3. Piston sleeve
4. Piston retur n spring
5. Spring retainer
6. Snap ring
7. Thrust washer (Plastic)
8. Second brake assembly

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–161
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Important operations
1. O–ring
Coat new O–ring with ATF and install them on the second
brake piston.
2. Second brake piston
Being careful not to damage the O–rings, press in the
second brake piston into the second brake drum.
3. Piston sleeve
Install piston sleeve.
4. Piston return spring
Install piston return spring.
5. Spring retainer
Install spring retainer.
6. 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.
Check second brake piston movement
Make sure the second brake piston moves smoothly when
applying and releasing the low compressed air to the
second brake drum.

7A–162 AUTOMATIC TRANSMISSION (AW30-40LE)
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7. Thrust washer (Plastic)
Coat the thrust washer with petroleum jelly and install it to
the second brake piston, with the grooved side facing
upward.
NOTE:
Make sure that the cutout portions of the thrust washer
match the teeth of the spring retainer.
8. Second brake assembly
Install second brake assembly to output shaft.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–163
REAR PLANETARY GEAR ASSEMBLY AND OUTPUT SHAFT
DISASSEMBLY
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Disassembly steps
1. Second brake assembly
2. Output shaft
3. Oil seal ring
4. Disc, plate and flange
5. Rear planetary gear assembly
6. One–way clutch inner race
7. Snap ring

8. One–way clutch
9. Thrust washer (Plastic)
10. Thrust washer (Plastic)
11. Thrust bearing and race
12. Snap ring
13. Ring gear flange

7A–164 AUTOMATIC TRANSMISSION (AW30-40LE)
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Important operations
3. Oil seal ring
Remove oil seal ring from output shaft.
5. Rear planetary gear assembly
Remove rear planetary gear from rear planetary ring gear.
Check operation of No.2 one–way clutch
Hold the planetary gear and turn the one–way clutch inner
race. The one–way clutch inner race should turn freely
counterclockwise and should lock clockwise.
(1) : Lock
(2) : Free
6. One–way clutch inner race
Remove the one–way clutch inner race from the rear
planetary gear.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–165
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7. Snap ring
Remove the snap ring with a screwdriver.
8. One–way clutch
Remove the one–way clutch with retainers from the
planetary gear.
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.

7A–166 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY
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Reassembly steps
1. Ring gear flange
2. Snap ring
3. Thrust bearing and race
4. Thrust washer (Plastic)
5. Thrust washer (Plastic)
6. One–way clutch
7. Snap ring
8. One–way clutch inner race
9. Rear planetary gear assembly
10. Disc, plate, and flange
11. Oil seal ring
12. Output shaft
13. Second brake assembly

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–167
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Important operations
1. Ring gear flange
Install ring gear flange to the ring gear.
2. Snap ring
Install snap ring to the ring gear.
3. Thrust bearing and race
Coat the races and bearing with petroleum jelly, and install
them onto the rear planetary ring gear.
4. Thrust washer (Plastic)
5. Thrust washer (Plastic)
Coat the thrust washer with petroleum jelly.
Install the thrust washer onto both sides of the rear
planetary gear, facing the grooved side upward.
NOTE:
Make sure that the lugs fit into the cutout portions on the
rear planetary gear.
6. One–way clutch
Install the one–way clutch with the flanged side facing
upward onto the rear planetary gear. Races and bearing diameter (Reference) mm (in.)
Inside Outside
Race (A) 28.8 (1.134) 44.8 (1.764)
Bearing 30.1 (1.185) 44.7 (1.760)
Race (B) 27.8 (1.095) 44.8 (1.764)

7A–168 AUTOMATIC TRANSMISSION (AW30-40LE)
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7. Snap ring
Install snap ring.
8. One–way clutch inner race
While turning counterclockwise, install one–way clutch
inner race to rear planetary gear.
Check operation of one–way clutch
Hold the planetary gear and turn the one–way clutch inner
race. The one–way clutch inner race should turn freely
counterclockwise and should lock clockwise.
(1) : Lock
(2) : Free
9. Rear planetary gear assembly
Install rear planetary gear onto rear planetary ring gear.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–169
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10. Disc, plate, and flange
Install a clutch plate onto the rear planetary gear assembly.
NOTE:
The claw interval of the plate should be as shown in the
figure when viewing the clutch plate from the arrow
direction.
Install a brake flange onto the rear planetary gear
assembly.
Install seven clutch discs and seven brake plates
alternately, star ting with clutch disc, onto the rear planetary
gear assembly.
11. Oil seal ring
Coat the oil seal ring with ATF and install it to the output
shaft.
NOTE:
Do not spread the ring ends too much.
12. Output shaft
Install output shaft into rear planetary assembly.