OPEL FRONTERA 1998 Workshop Manual

7A–200 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00013
240RY00014
240RY00027
Important operations
1. Second brake drum gasket
Install a new brake drum gasket to the transmission case.
Individual piston operation inspection
Check for the sound of operation while injecting
compressed air into the oil hole indicated in the figure.
NOTE:
When inspecting the direct clutch, check with the C–0
accumulator piston hole closed. If there is no noise,
disassemble and check the condition of the parts.
A : C–0 Accumulator piston hole
2. Accumulator piston
Coat the O–ring with ATF and install it to the piston.
Install the five springs and four accumulator pistons to the
bore as shown in the figure. 1: OD direct clutch 5: Second coast brake
2: Direct clutch 6. Second brake
3: Forward clutch 7. First and reverse brake
4: OD brake

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–201
240RY00015
240RY00029
240RY00010
240RY00016
3. Check valve, spring
Install new check valve and spring.mm (in.)
Piston Outer diameter Height
B–2 36.8 (1.449) 62.5 (2.461)
C–2 36.8 (1.449) 56.6 (2.228)
B–0 31.8 (1.252) 52.0 (2.047)
C–0 29.8 (1.173) 44.0 (1.732)
Spring Free length Outer diameter
(1) B–2 75.8 (2.984) 20.1 (0.791)
(2) C–2 (Inner) 42.1 (1.658) 14.7 (0.579)
(3) C–2 (Outer) 64.0 (2.520) 20.2 (0.795)
(4) B–0 63.6 (2.504) 16.0 (0.630)
(5) C–0(Outer) 74.6 (2.937) 20.9 (0.823)
(6) C–0(Inner) 46.0 (1.811) 14.0 (0.551)

7A–202 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00017
244RY00017
249RY00011
249RY00012
4. Valve body
Align the groove of the manual valve to the pin of the lever.
Install the twenty bolts.
Each bolt length (mm) is indicated in the figure.
5. Solenoid wiring
Coat a new O–ring with ATF, and install it to the solenoid
wiring.
Insert the solenoid wiring to the case and install the stopper
plate.
Connect the connectors to the solenoid S1(1), S2(2), lock-
up solenoid (3), and pressure control solenoid (4).Nꞏm (kgꞏm/lbꞏin)
Torque 10 (1.0/87)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–203
244RY00002
244RY00003
240RY00019
240RY00020
6. Oil strainer assembly
Install a new oil strainer assembly with gaskets.
Install the oil strainer with the gaskets to the valve body.
Tighten the four bolts.
7. Oil pan
Install magnet in pan.
Remove any packing material and be careful not to drop oil
on the contacting surfaces of the transmission case and oil
pan.
Apply liquid gasket (TB1281 or its equivalent) to the oil pan
as shown in the figure.
NOTE:
Install the oil pan as soon as the seal packing is applied.
Install and tighten the nineteen bolts.Nꞏm (kgꞏm/lbꞏin)
Torque 10 (1.0/87)
Nꞏm (kgꞏm/lbꞏin)
To r q u e 8 ( 0 . 8 / 6 9 )

7A–204 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY OF MAJOR COMPONENTS (3)
240RY00030
Reassembly steps
1. Transmission assembly
2. Converter housing
3. Adapter housing
4. Oil temperature sensor
5. Elbow
6. Neutral star t switch
7. Transmission control rod and shift lever
8. Input revolution sensor
9. Output revolution sensor
10. Breather hose

11. Torque converter

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–205
240RY00006
240RY00003
241RY00020
Important operations
2. Converter housing
3. Adapter housing
Oil seal replacement
(1)Using a screwdriver, remove the oil seal.
(2)Apply ATF to a new oil seal lip.
(3)Using special tool, install the oil seal.
Installer:5–8840–2282–0
Remove any gasket material on the contacting surfaces of
the adapter case and transmission case.
Apply liquid gasket (TB1281–B or its equivalent) (1) and
install the apply gaskets (2) to the adapter case as shown
in the figure.
Install the adapter housing to the transmission case.
4. Oil temperature sensor
Install the oil temperature sensor to the transmission case.Nꞏm (kgꞏm/lbꞏft)
To r q u eM10 34 (3.5/25)
M12 57 (5.8/42)
Nꞏm (kgꞏm/lbꞏft)
Torque 34 (3.5/25)
Nꞏm (kgꞏm/lbꞏft)
Torque 15 (1.5/11)

7A–206 AUTOMATIC TRANSMISSION (AW30-40LE)
249RW003
249RY00008
240RY00005
5. Elbow
Coat new O–rings with ATF, install them to the two elbows.
Install the elbows as shown in the figure.
6. Neutral start switch
Using the control shift lever, fully turn the manual lever shaft
back and return two notches. It is now in neutral.
Insert the neutral star t switch onto the manual valve shaft
and temporarily tighten the adjusting bolt.
Install the lock washer and install and torque the nut.
Align the neutral standard line and the switch groove and
tighten the adjusting bolt.
Bend the tabs of the lock washer.
NOTE:
Bend at least two of the lock washer tabs.
7. Control rod and shift lever
Install control shift lever.
11. Torque converter
Using calipers and a straight edge, measure from the
installed surface of the transmission housing.Nꞏm (kgꞏm/lbꞏft)
Torque 29 (3.0/22)
Nꞏm (kgꞏm/lbꞏin)
To r q u e 7 ( 0 . 7 / 6 1 )
Nꞏm (kgꞏm/lbꞏin)
Torque 13 (1.3/113)
Nꞏm (kgꞏm/lbꞏft)
Torque 29 (3.0/22)
mm (in.)
Correct distance 67(2.64) or more

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–207
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS

7A–208 AUTOMATIC TRANSMISSION (AW30-40LE)
TORQUE SPECIFICATIONS
Nꞏm (kgꞏm/lbꞏft)
E07RY00009

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–209
TORQUE SPECIFICATIONS
Nꞏm (kgꞏm/lbꞏft)
E07RY00006