OPEL FRONTERA 1998 Workshop Manual

7A–180 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00021
249RY00005
249RY00006
249RY00003
Important operations
1. Oil seal
2. Oil seal
Coat a new oil seal lip with multi purpose grease.
Using special tool, drive in the oil seal.
Oil seal installer : 5–8840–2169–0 (J–37232–2)
3. Spacer
4. Manual valve lever
Assemble a new spacer to the manual valve lever.
5. Manual valve lever shaft
Install the manual valve lever shaft to the transmission case
through the manual valve lever by the threads.
6. Pin
Drive in the pin with the slot at a right angle to the shaft.
Match the spacer hole to the lever staking hollow and stake
the spacer to the lever.
Make sure the manual valve lever shaft turns smoothly.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–181
241RY00018
TORQUE CONVERTER
INSPECTION AND REPAIR
Insert special tool in end of torque converter
Insert a turning tool into the inner race of the one–way
clutch.
One–way clutch testing tool : 5–8840–2168–0 (J–35467)
Insert the stopper so that it fits in the notch of the converter
hub and outer race of the one–way clutch.
Test one–way clutch
The clutch should lock when turned counterclockwise, and
rotate freely and smoothly clockwise. Less than 25kgꞏcm
(22 Ibꞏin) of torque should be required to rotate the clutch
clockwise. If necessary, clean the conver ter and retest the
clutch. Replace the converter if the clutch still fails the test.

7A–182 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY OF MAJOR COMPONENTS
Disassembly, inspection and reassembly of each
component group have been indicated in the preceding
chapter. Before reassembly, make sure, again, that all
component groups are assembled correctly.
If something wrong is found in a certain component group
during assembly, inspect and repair this group immediately.
GENERAL ASSEMBLY NOTES:
1. The automatic transmission is composed of highly
precision–finished parts, necessitating careful inspection
before assembly because even a small nick could cause
fluid leakage or affect performance.
2. Before assembling new clutch discs and brake bands, soak
them in automatic transmission fluid for at least thir ty
minutes.
3. Apply automatic transmission fluid on the sliding or rotating
surfaces of parts before assembly.
4. Use petroleum jelly to keep small par ts in their places.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new
gaskets and O–rings.
7. Dry all par ts with compressed air - never use shop rags.
8.Be sure to install the thrust bearings and races in the
correct direction and position.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–183
240RY00022

7A–184 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY OF MAJOR COMPONENTS (1)
248L100002
Reassembly steps
1. Bearing
2. Rear planetary gear, second brake drum
and output shaft
3. Snap ring
4. Second brake piston sleeve
5. One–way clutch
6. Flange plate and disc
7. Snap ring
8. Drum
9. Front planetary gear and bearing
10. Snap ring
11. Race
12. Second coast brake band
13. E–ring and pin
14. Bearing and race
15. Race
16. Front planetary ring gear
17. Bearing and race
18. Direct clutch and forward clutch
19. Second coast brake piston assembly
20. Snap ring
21. Race

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–185
22. OD suppor t
23. Snap ring
24. Flange, plate and disc
25. Snap ring
26. Bearing and race
27. OD planetary ring gear
28. Bearing and race
29. Race
30. OD planetary gear and OD direct clutch
31. Bearing
32. Race
33. Oil pump

7A–186 AUTOMATIC TRANSMISSION (AW30-40LE)
247RY00008
247RY00009
247RY00010
246RY00003
Important operations
1. Bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the case.
2. Rear planetary gear, second brake drum and output
shaft
Align the teeth of the second brake drum, flanges, discs
and plates as shown in the figure.
Align the splines of the transmission case and the
assembled rear planetary gear, second brake drum and
output shaft, indicated by A in the figure at left.
3. Snap ring
Using snap ring pliers, install the snap ring. Assemble bearing and race (reference) mm (in.)
Bearing and race Diameter
Inside 39.2 (1.543)
Outside 57.7 (2.272)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–187
248RY00016
246RY00004
247RY00011
246RY00005
Check pack clearance of first and reverse brake
Using a thickness gauge, measure the clearance between
the plate and second brake drum as shown in the figure.
If the values are nonstandard, check for an improper
installation.
4. Second brake piston sleeve
Install second brake piston sleeve.
5. One–way clutch
Install one–way clutch.
6. Flange plate and disc
Install flange, discs and plates.
Install the 2.5mm (0.098in.) thick plate with the rounded
edge side of the plate facing the disc.
Alternately install four discs and three plates (Disc first)
Install the flange with the rounded edge of the flange facing
the disc.mm (in.)
Clearance 0.7–1.0
(0.0276–0.0394)

7A–188 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00014
248RY00019
248RY00020
247RY00012
7. Snap ring
Install the snap ring.
Check pack clearance of second brake
Using a thickness gauge, measure the clearance between
the snap ring and flange as shown in the figure.
If the values are nonstandard, check for an improper
installation.
8. Drum
While turning the sun gear input drum clockwise, install it
into the one-way clutch.
NOTE:
Confirm the thrust washers are installed correctly.
9. Front planetary gear and bearing
Install the front planetary gear to the sun gear.
NOTE:
Confirm the bearing and race is installed correctly.mm (in.)
Clearance0.62–1.98
(0.0244–0.0780)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–189
247RY00013
248RY00017
247RY00014
248RY00010
With wooden blocks under the output shaft, stand the
transmission on the output shaft.
10. Snap ring
Using snap ring pliers, install the snap ring.
11. Race
Coat the bearing race with petroleum jelly and install it onto
the front planetary gear.
12. Second coast brake band
Insert the second coast brake band to the case. Bearing race diameter (Reference) mm (in.)
Bearing race Diameter
Inside 34.3 (1.350)
Outside 47.8 (1.882)