OPEL FRONTERA 1998 Workshop Manual

7A–190 AUTOMATIC TRANSMISSION (AW30-40LE)
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13. E–ring and pin
Install the pin through the brake band.
Install the E–ring to the pin.
14. Bearing and race
Coat the bearing and race with petroleum jelly and install
them onto the forward clutch.
15. Race
Coat the race with petroleum jelly and install it onto the
front planetary ring gear. Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing 26.0 (1.024) 46.7 (1.839)
Race 26.0 (1.024) 48.9 (1.925)
Race diameter (Reference) mm (in.)
Inside Outside
Race 26.8 (1.055) 47.0 (1.850)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–191
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Align the flukes of the discs in the forward clutch.
16. Front planetary ring gear
Align the spline of th front planetary gear with the flukes of
the discs and install the front planetary gear to the forward
clutch.
17. Bearing and race
Coat the bearing and race with petroleum jelly and install
them onto the ring gear.
18. Direct clutch and forward clutch
Install the assembled direct clutch, forward clutch and front
planetary ring gear into the transmission case. Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing 32.6 (1.283) 47.7 (1.878)
Race 30.6 (1.205) 53.6 (2.110)

7A–192 AUTOMATIC TRANSMISSION (AW30-40LE)
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Using vernier calipers, measure the distance between the
sun gear input drum and direct clutch drum as shown in the
figure.
If the values are nonstandard, check for an improper
installation.
Coat the assembled bearing and race with petroleum jelly
and install it onto the forward clutch.
19. Second coast brake piston assembly
Coat the oil seal ring with ATF and install it to the second
coast brake piston.
Install the washer, spring and piston to the piston rod.
Install the E–ring.
(1): Second coast brake piston
(2): Oil seal
(3): Piston rod
20. Snap ring
Coat two new oil seals with ATF and install them to the
piston cover.
Install the spring, second coast brake piston assembly and
piston cover to the case.
Using snap ring pliers, install the snap ring.mm (in.)
Height9.8 – 11.8
(0.386 – 0.465)
Assembled bearing and race diameter (Reference)
mm (in.)
Inside Outside
Bearing
and race33.7 (1.327) 47.8 (1.882)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–193
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Check piston stroke of second coast brake
Place a mark on the second coast brake piston rod as
shown in the figure.
Using wire gage, measure the stroke by applying the
compressed air (4–8kg/cm
2, 57–114 psi or 392–785kPa)
as shown in the figure.
If the values are nonstandard, check for an improper
installation.
21. Race
Coat the race with petroleum jelly and install it onto the
overdrive suppor t assembly.
22. OD support
Aim the bolt and oil holes of the overdrive suppor t toward
the valve hole side, and align them with the bolt hole of the
transmission case and insert.mm (in.)
Piston stroke1.5–3.0
(0.059–0.118)
Race diameter (Reference) mm (in.)
Inside Outside
Race 36.8 (1.450) 50.9 (2.004)

7A–194 AUTOMATIC TRANSMISSION (AW30-40LE)
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23. Snap ring
Using snap ring pliers, install the snap ring as shown in the
figure.
Install and tighten the two bolts.
Check end of output shaft
Using a dial indicator, measure the end play of the output
shaft by hand.
24. Flange, plate and disc
Install the (flat ring) 4.0 mm (0.157 in.) thick flange with the
rounded edge side of the flange facing the disc.
Alternately install four discs and three plates. (Disc first)Nꞏm(kgꞏm / lbꞏft)
Torque 25 (2.6/19)
mm (in.)
End play0.27–0.86
(0.0106–0.0339)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–195
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25. Snap ring
Install the (stepped ring) flange with the flat side of the
flange facing the disc.
Install the snap ring.
Check piston stroke of overdrive brake
Place a dial indicator onto the overdrive brake piston as
shown in the figure.
Measure the stroke by applying and releasing the
compressed air (4–8kg/cm
2, 57–114–psi or 392–785 kPa)
as shown in the figure.
If the values are nonstandard, select another flange.
Remove the snap ring. Snap ring (Reference) mm (in.)
Inside diameter 167.9 (6.61)
mm (in.)
Piston stroke1.40–1.70
(0.0551–0.0670)
Available Flange size mm(in.)
3.3 (0.130) 3.8 (0.150)
3.5 (0.138) 3.9 (0.154)
3.6 (0.142) 4.0 (0.158)
3.7 (0.146)

7A–196 AUTOMATIC TRANSMISSION (AW30-40LE)
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Remove two flanges, three plates and four discs.
26. Bearing and race
Coat the bearing and races with petroleum jelly and install
them onto the overdrive support.
27. OD planetary ring gear
Install the overdrive planetary ring gear.
28. Bearing and race
Coat the bearing and race with petroleum jelly and install
them onto the planetary ring gear. Bearing and races diameter (Reference) mm (in.)
Inside Outside
Bearing 36.5 (1.437) 48.5 (1.910)
Race (Front) 37.2 (1.465) 58.8 (2.315)
Race (Rear) 33.7 (1.327) 50.1 (1.973)
Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing 26.0 (1.024) 46.8 (1.843)
Race 24.2 (0.953) 47.8 (1.882)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–197
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29. Race
Coat the race with petroleum jelly and install it onto the
planetary gear.
30.OD planetary gear and OD direct clutch
Install the overdrive planetary gear and direct clutch.
31.Bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the direct clutch.
Install the (flat ring) 4.0mm (0.157 in.) thick flange with the
rounded edge side of the flange facing the disc.
Alternately install three discs and two plates. (Disc first) Race diameter (Reference) mm (in.)
Inside Outside
Race 27.3 (1.075) 41.8 (1.646)
Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing and
race28.9 (1.138) 50.2 (1.976)

7A–198 AUTOMATIC TRANSMISSION (AW30-40LE)
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Install the (stepped ring) flange with the flat side of the
flange facing the disc.
Install the snap ring.
32.Race
Coat the race with petroleum jelly and install it onto the oil
pump.
33.Oil pump
Coat the O–ring with ATF and install it around the pump
body.
Place the oil pump through the input shaft, and align the
bolt holes of the pump body with the transmission case.
Hold the input shaft, and lightly press the oil pump body to
slide the oil seal rings on the stator shaft through the direct
clutch drum.
NOTE:
Do not push on the oil pump strongly or the oil seal ring
will stick to the direct clutch drum.
Install the seven bolts.
Check input shaft rotation
Make sure the input shaft rotates smoothly. Race diameter (Reference) mm (in.)
Inside Outside
Race 28.1 (1.106) 47.3 (1.862)
Nꞏm(kgꞏm / lbꞏft)
Torque 22 (2.2/16)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–199
REASSEMBLY OF MAJOR COMPONENTS (2)
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Reassembly steps
1. Second brake drum gasket
2. Accumulator piston
3. Check valve, spring
4. Valve body
5. Solenoid wiring
6. Oil strainer assembly
7. Oil pan