1998 OPEL FRONTERA brake

7A–182 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY OF MAJOR COMPONENTS
Disassembly, inspection and reassembly of each
component group have been indicated in the preceding
chapter. Before reassembly, make sure, again, that all
component groups are assembled correctly.
If something wrong is found in a certain component group
during assembly, inspect and repair this group immediately.
GENERAL ASSEMBLY NOTES:
1. The automatic transmission is composed of highly
precision–finished parts, necessitating careful inspection
before assembly because even a small nick could cause
fluid leakage or affect performance.
2. Before assembling new clutch discs and brake bands, soak
them in automatic transmission fluid for at least thir ty
minutes.
3. Apply automatic transmission fluid on the sliding or rotating
surfaces of parts before assembly.
4. Use petroleum jelly to keep small par ts in their places.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new
gaskets and O–rings.
7. Dry all par ts with compressed air - never use shop rags.
8.Be sure to install the thrust bearings and races in the
correct direction and position.

7A–184 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY OF MAJOR COMPONENTS (1)
248L100002
Reassembly steps
1. Bearing
2. Rear planetary gear, second brake drum
and output shaft
3. Snap ring
4. Second brake piston sleeve
5. One–way clutch
6. Flange plate and disc
7. Snap ring
8. Drum
9. Front planetary gear and bearing
10. Snap ring
11. Race
12. Second coast brake band
13. E–ring and pin
14. Bearing and race
15. Race
16. Front planetary ring gear
17. Bearing and race
18. Direct clutch and forward clutch
19. Second coast brake piston assembly
20. Snap ring
21. Race

7A–186 AUTOMATIC TRANSMISSION (AW30-40LE)
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Important operations
1. Bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the case.
2. Rear planetary gear, second brake drum and output
shaft
Align the teeth of the second brake drum, flanges, discs
and plates as shown in the figure.
Align the splines of the transmission case and the
assembled rear planetary gear, second brake drum and
output shaft, indicated by A in the figure at left.
3. Snap ring
Using snap ring pliers, install the snap ring. Assemble bearing and race (reference) mm (in.)
Bearing and race Diameter
Inside 39.2 (1.543)
Outside 57.7 (2.272)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–187
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Check pack clearance of first and reverse brake
Using a thickness gauge, measure the clearance between
the plate and second brake drum as shown in the figure.
If the values are nonstandard, check for an improper
installation.
4. Second brake piston sleeve
Install second brake piston sleeve.
5. One–way clutch
Install one–way clutch.
6. Flange plate and disc
Install flange, discs and plates.
Install the 2.5mm (0.098in.) thick plate with the rounded
edge side of the plate facing the disc.
Alternately install four discs and three plates (Disc first)
Install the flange with the rounded edge of the flange facing
the disc.mm (in.)
Clearance 0.7–1.0
(0.0276–0.0394)

7A–188 AUTOMATIC TRANSMISSION (AW30-40LE)
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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
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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)

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)

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)