1998 OPEL FRONTERA oil pump

7A–87 AUTOMATIC TRANSMISSION (4L30–E)
(38) Seal, O–Ring
(39) Reservoir
(42) Gasket, Extension Case
(43) Extension Assembly
(44) Seal, O–Ring/Speed Sensor
(45) Sensor Assembly, Speed
(46) Screw, Speed Sensor
(50) Seal, Extension Assembly
(52) Screw, Extension/Main Case
(53) Spring, Parking Pawl Lock
(54) Pawl, Parking Lock
(55) Connector, Electrical/Main Case
(56) Actuator Assembly, Parking Lock
(57) Nut, Parking Lock Lever
(58) Link, Manual Valve
(59) Pin, Spring
(60) Lever, Parking Lock and Range Selector
(61) Shaft, Selector
(62) Seal, Selector Shaft
(63) Mode Switch Assembly
(64) Screw and Conical Washer Assembly
(65) Shield, Mode Switch
(67) Pan, Bottom/Adapter Case
(68) Gasket, Bottom Pan/Adapter Case
(69) Harness Assembly, Adapter Case
(70) Screw, Valve Body
(71) Valve Body Assembly, Adapter Case
(72) Gasket, Adapter Valve Body
(73) Plate, Adapter Valve Body/Transfer
(74) Pan, Bottom/Main Case(75) Gasket, Bottom Pan/Main Case
(76) Gasket, Oil Drain or Overfill Screw
(77) Screw, Oil Drain or Overfill
(78) Magnet, Chip Collector
(79) Filter Oil
(80) Harness Assembly, Main Case
(82) Roller and Spring Assembly, Manual Detent
(84) Valve Body Assembly, Main Case
(85) Ball, Check
(86) Gasket, Main V.B./Transfer Plate
(87) Plate, Main V.B./Transfer
(88) Gasket, Transfer/Main Case
(89) Screw, Transfer Plate on V.B.
(90) Screw, Servo Cover
(91) Cover, Servo Piston
(92) Gasket, Cover/Servo Piston
(93) Ring, Retaining Servo Piston
(94) Clip, Servo Piston
(95) Nut, Servo Screw
(96) Screw, Servo Piston
(97) Piston, Servo
(98) Seal, Ring/Servo Piston
(99) Spring, Cushion/Servo Piston
(100) Seat, Cushion Spring
(101) Sleeve, Servo Piston Adjust
(102) Rod, Apply/Servo Piston
(103) Spring, Return/Servo Piston
(104) Gasket, Adapter Case/Transfer Plate
(105) Powertrain Control Module
(106) Servo Piston Assembly
Pump Assembly
241RS019
Legend
(201) Gear, Oil Pump Drive
(202) Gear, Oil Pump Driven
(203) Pin, Boost Valve Sleeve
(204) Sleeve, Boost Valve(205) Valve, Boost
(206) Seat, Spring/Pressure Regulator Valve
(207) Spring, Pressure Regulator Valve
(208) Valve, Pressure Regulator
(209) Pump Assembly, Oil

7A–2 AUTOMATIC TRANSMISSION (AW30-40LE)
VALVE BODY ASSEMBLY AND PRESSERE CONTOROL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . 7A–84
TRANSMISSION REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–86
UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–91
DISASSEMBLY OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–91
DISASSEMBLY, INSPECTION AND REASSEMBLY OF MINOR COMPONENTS. . . . . . . . . . . . . . . . . 7A–107
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–108
OD PLANETARY GEAR AND OD DIRECT CLUTCH ASSEMBLY (C-0) . . . . . . . . . . . . . . . . . . . . . . . . 7A–114
OD SUPPORT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–126
DIRECT CLUTCH ASSEMBLY (C-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–133
FORWARD CLUTCH ASSEMBLY (C-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–141
FRONT PLANETARY GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–150
PLANETARY SUN GEAR AND NO.1 ONE–WAY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–153
SECOND BRAKE ASSEMBLY (B–2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–158
REAR PLANETARY GEAR ASSEMBLY AND OUTPUT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–163
FIRST AND REVERSE BRAKE (B–3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–171
TRANSMISSION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–177
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–181
REASSEMBLY OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–182
MAIN DATA AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–207
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–207
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–208
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–211
CAUTION: When fasteners are removed, always
reinstall them at a the same location from which
they were removed. If a fastener needs to be
replaced, use the correct part number fastener for
that application. If the correct part number fastener
is not available, a fastener of equal size and
strength (or stronger) may be used. Fasteners that
are not reused, and those requiring thread locking
compound, will be called out. The correct torque
values must be used when installing fasteners that
require torque. If the above conditions are not
followed, parts or system damage could result.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–65
F07RY00004
HYDRAULIC TEST
PREPARATION
1) Warm up the transmission fluid.
2) Remove the transmission case test plug and mount the
hydraulic pressure gauge.
Oil pressure gauge: 5-8840-0093-0
NOTE:
Perform the test at normal operating fluid temperature (50
– 80
C or 122 – 176F).
MEASURE LINE PRESSURE
1) Fully apply the parking brake and chock the four wheels.
2) Start the engine and check idling rpm.
3) Shift into "D" range, step down strongly on the brake pedal
with your left foot and, while manipulating the accelerator
pedal with the right foot, measure the line pressures at the
engine speeds specified in the table.
4) In the same manner, perform the test in "R" range.
EVALUATION
1) If the measured values at all ranges are higher than
specified.
• Pressure control solenoid defective.
• Primary regulator valve defective.
2) If the measured values at all ranges are lower than
specified.
• Primary regulator valve defective.
• Oil pump defective.
• Pressure control solenoid defective.
3) If pressure is low in "D" range only:
• "D" range circuit fluid leakage.
4) If pressure is low in "R" range only:
• "R" range circuit fluid leakage. Engine
speedLine pressure kPa (kg/cm
2/psi)
"D" range "R" range
Idling 358 – 417
(3.6–4.3 / 51–61)588 – 686
(6.0–7.0 / 85–100)
Stall 1,176 – 1,323
(12.0–13.5 / 171–192)1,607 – 1,940
(16.4–19.8 / 233–282)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–97
DISASSEMBLY OF MAJOR COMPONENTS (3)
248L100001
Disassembly steps
1. Oil pump
2. Race
3. OD planetary gear and OD direct clutch
4. Race
5. OD planetary ring gear
6. Snap ring
7. Flange, plate and disc
8. Bearing and race
9. Snap ring
10. OD suppor t
11. Race
12. Snap ring
13. Second coast brake piston assembly
14. Direct clutch and forward clutch
15. E-ring and pin
16. Second coast brake band
17. Front planetary ring gear
18. Bearing and race
19. Race
20. Snap ring
21. Front planetary gear
22. Drum and one-way clutch
23 Snap ring
24. Flange, plate and disc
25. Snap ring
26. Rear planetary gear, second brake drum
and output shaft
27. Bearing

7A–98 AUTOMATIC TRANSMISSION (AW30-40LE)
241RY00003
241RY00002
252L100001
252L100017
Important operations
1. Oil pump
Remove seven bolts fixing the oil pump to the transmission
case.
Remove the oil pump.
2. Race
Remove race from oil pump.
3. OD planetary gear and OD direct clutch
Remove the overdrive planetary gear and overdrive direct
clutch with thrust needle bearing from the transmission
case.
4. Race
Remove the race from OD planetary gear.

7A–108 AUTOMATIC TRANSMISSION (AW30-40LE)
OIL PUMP
DISASSEMBLY
241RY00004
241RY00005
Important operations
1. Oil seal ring
Use torque converter as work stand.
Remove 2 oil seal rings from stator shaft.
2. O-ring
Remove O-ring.
Disassembly steps
1. Oil seal ring
2. O-ring
3. Stator shaft 4. Oil pump drive gear
5. Oil pump driven gear

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–109
241RY00006
241RY00007
241RY00008
3. Stator shaft
Remove 13 bolts, and then remove the stator shaft from oil
pump body.
Then remove drive and driven gear.
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
Check oil pump body bushing
Using a dial indicator, measure the inside diameter of the
oil pump body bushing.
If the inside diameter is greater than the maximum, replace
the oil pump body.
Check stator shaft bushing
Using a dial indicator, measure the inside diameter of the stator
shaft bushing.
If the inside diameter is greater than maximum, replace the
stator shaft.mm (in.)
Maximum inside diameter 38.19 (1.5035)
mm (in.)
Maximum inside
diameterFront side 21.58 (0.8496)
Rear side 27.08 (1.0661)

7A–110 AUTOMATIC TRANSMISSION (AW30-40LE)
241RY00009
241RY00010
241RY00011
241RY00012
Check tip clearance of both gears
Measure between the gear teeth and the cresent-shaped
par t of the pump body.
If the tip clearance is greater than the maximum, replace
the drive gear, driven gear or pump body.
Check body clearance of driven gear
Push the driven gear to one side of the body.
Use a feeler gauge, measure the clearance.
If the body clearance is greater than the maximum, replace
the drive gear, driven gear or pump body.
Check side clearance of both gears
Using a steel straightedge and a feeler gauge, measure the
side clearance of both gears.
If the side clearance is greater than the maximum, replace
the drive gear, driven gear or pump body.
Check oil seal
Check for wear, damage or cracks.
If necessary, replace oil seal.
Pry off the oil seal with a screwdriver.mm (in.)
Standard tip clearance0.11–0.14
(0.0043–0.0055)
Maximum tip clearance 0.3 (0.012)
mm (in.)
Standard body clearance0.07–0.15
(0.0028–0.0059)
Maximum body clearance 0.3 (0.012)
mm (in.)
Standard side clearance0.02–0.05
(0.0008–0.0020)
Maximum side clearance 0.1 (0.004)