lock OPEL FRONTERA 1998 Workshop Manual

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–125
252L100015
252L100004
252L100003
15. Thrust bearing
Coat the assembled bearing and race with petroleum jelly
and install it with the race side facing downward.
16. OD direct clutch assembly
Align the flukes of discs in the direct clutch .
Install the OD direct clutch assembly onto the OD planetary
gear.
Check operation of one-way clutch.
Hold the OD direct clutch drum and turn the input shaft.
The input shaft should turn freely clockwise and should lock
counterclockwise.
(1): Free
(2): Lock Assembled bearing and race (Reference) mm (in.)
Inside diameter 28.9 (1.138)
Outside diameter 50.2 (1.976)

7A–142 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00039
248RY00048
248RY00040
248RY00041
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)

7A–154 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00051
248RY00052
248RY00053
248RY00054
Important operations
Check operation of No.1 one–way clutch
Hold the planetary sun gear and turn the second brake
hub. The second brake hub should turn freely clockwise
and should lock counterclockwise.
(1) : Free
(2) : Lock
3. Oil seal ring (Metal)
Remove two oil seal rings.
4. Snap ring
Remove the snap ring with snap ring pliers.
INSPECTION AND REPAIR
Check planetary sun gear bushing
Using a dial indicator, measure the inside diameter of the
planetary sun gear bushing.
If the inside diameter is greater than the maximum, replace
the planetary sun gear.mm (in.)
Maximum inside diameter 27.08 (1.0661)

7A–156 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00055
248RY00056
248RY00053
248RY00052
Important operations
1. Snap ring
Install snap ring to planetary sun gear.
2. Sun gear input drum
Place a wooden block, etc. as a work stand and place the
planetary sun gear onto it.
Install the sun gear input drum onto the planetary sun gear.
3. Snap ring
Install snap ring with snap ring pliers.
4. Oil seal ring (Metal)
Coat the two oil seal rings with ATF.
Install the two oil seal rings onto the planetary sun gear.
NOTE:
Do not spread the ring ends too much.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–157
248RY00057
248RY00058
248RY00051
5. Thrust washer (plastic)
Install thrust washer.
NOTE:
Make sure that the lugs fit into the holes on the sun gear
input drum.
6. One–way clutch and second brake hub
Install assembled No.1 one–way clutch and second brake
hub onto planetary sun gear as shown.
Check operation of No.1 one–way clutch
Hold the planetary sun gear and turn the second brake
hub. The second brake hub should turn freely clockwise
and should lock counterclockwise.
(1) : Free
(2) : Lock

7A–164 AUTOMATIC TRANSMISSION (AW30-40LE)
247RY00028
247RY00029
247RY00030
247RY00031
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.

7A–168 AUTOMATIC TRANSMISSION (AW30-40LE)
247RY00039
247RY00040
247RY00041
247RY00029
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–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–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)