1998 OPEL FRONTERA clutch

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)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–127
252RY00042
252RY00043
252RY00044
252RY00045
Important operations
Check OD brake piston
Place the OD suppor t assembly onto the direct clutch
assembly.
Apply compressed air into the oil passage as shown, and be
sure that the OD brake piston moves smoothly.
4. Snap ring
Place special tool on the spring retainer, and compress the
return spring with a shop press.
Spring compressor: 5-8840-2170-0 (J-37233)
Remove the snap ring with a screwdriver.
6. OD brake piston
Place the OD suppor t onto the direct clutch assembly.
Hold the OD brake piston so it is not slanted and apply
compressed air into the passage to remove the OD brake
piston.
Remove the OD brake piston.

7A–132 AUTOMATIC TRANSMISSION (AW30-40LE)
252RY00042
252RY00043
Check OD brake piston
Place the OD suppor t assembly onto the direct clutch
assembly.
Apply compressed air into the oil passage as shown, and be
sure that the OD brake piston moves smoothly.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–133
DIRECT CLUTCH ASSEMBLY (C-2)
DISASSEMBLY
248RY00059
Disassembly steps
1. Clutch drum thrust washer
2. Snap ring
3. Flange
4. Plate and disc
5. Snap ring
6. Piston return spring
7. Direct clutch piston
8. O-ring

7A–134 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00028
248RY00029
248RY00061
248RY00002
Important operations
Remove direct clutch drum assembly from forward clutch
assembly.
Check piston stroke of direct clutch (C-2)
Place the direct clutch assembly onto the OD suppor t
assembly.
Using a dial indicator, measure the direct clutch piston
stroke by applying and releasing compressed air (4– 8 kg/
cm
2, 57– 114 psi or 392– 785 kPa) as shown.
5. Snap ring
Place special tool and a suitable ring on the spring retainer
and compress the return spring. Using snap ring pliers,
remove the snap ring.
Spring compressor: 5-8840-0254-0 (J-25048)mm (in.)
Piston stroke1.6– 1.9
(0.0630– 0.0748)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–135
248RY00030
247RY00034
252RY00027
248RY00031
7. Direct clutch piston
Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply compressed
air to the OD support to remove the direct clutch piston.
Remove the direct clutch piston.
Remove two O-ring from piston.
INSPECTION AND REPAIR
Check piston return spring
Using calipers, measure the free length of the return spring.
Check discs
Using a micrometer, measure the thickness of the discs.
If the thickness is less than the minimum, replace the disc.
Check direct clutch piston
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying low-pressure
compressed air.mm (in.)
Standard 21.3 (0.839)
mm (in.)
Minimum thickness 1.84 (0.0724)

7A–136 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00032
Check direct clutch drum bushing
Using a dial indicator, measure the inside diameter of the
clutch drum bushing.
If the inside diameter is grater than maximum, replace the
clutch drum.mm (in.)
Maximum inside diameter 53.99 (2.1256)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–137
REASSEMBLY
248RY00060
Reassembly steps
1. O-ring
2. Direct clutch piston
3. Piston retur n spring
4. Snap ring
5. Disc and plate
6. Flange
7. Snap ring.
8. Clutch drum thrust washer (plastic)