1998 OPEL FRONTERA clutch

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–165
247RY00032
247RY00033
248RY00045
7. Snap ring
Remove the snap ring with a screwdriver.
8. One–way clutch
Remove the one–way clutch with retainers from the
planetary gear.
Check disc, plate and flange
Check to see if the sliding surface of the disc, plate and
flange are worn or burnt. If necessary, replace them.
• If the lining of the disc is peeling off or discolored, or even
if par ts of the printed numbers are defaced, replace all
discs.
• Before assembling new discs, soak them in ATF for at
least fifteen minutes.

7A–166 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY
247RY00046
Reassembly steps
1. Ring gear flange
2. Snap ring
3. Thrust bearing and race
4. Thrust washer (Plastic)
5. Thrust washer (Plastic)
6. One–way clutch
7. Snap ring
8. One–way clutch inner race
9. Rear planetary gear assembly
10. Disc, plate, and flange
11. Oil seal ring
12. Output shaft
13. Second brake assembly

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–167
247RY00035
247RY00036
247RY00037
247RY00038
Important operations
1. Ring gear flange
Install ring gear flange to the ring gear.
2. Snap ring
Install snap ring to the ring gear.
3. Thrust bearing and race
Coat the races and bearing with petroleum jelly, and install
them onto the rear planetary ring gear.
4. Thrust washer (Plastic)
5. Thrust washer (Plastic)
Coat the thrust washer with petroleum jelly.
Install the thrust washer onto both sides of the rear
planetary gear, facing the grooved side upward.
NOTE:
Make sure that the lugs fit into the cutout portions on the
rear planetary gear.
6. One–way clutch
Install the one–way clutch with the flanged side facing
upward onto the rear planetary gear. Races and bearing diameter (Reference) mm (in.)
Inside Outside
Race (A) 28.8 (1.134) 44.8 (1.764)
Bearing 30.1 (1.185) 44.7 (1.760)
Race (B) 27.8 (1.095) 44.8 (1.764)

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–169
246RY00013
247RY00047
247RY00028
247RY00042
10. Disc, plate, and flange
Install a clutch plate onto the rear planetary gear assembly.
NOTE:
The claw interval of the plate should be as shown in the
figure when viewing the clutch plate from the arrow
direction.
Install a brake flange onto the rear planetary gear
assembly.
Install seven clutch discs and seven brake plates
alternately, star ting with clutch disc, onto the rear planetary
gear assembly.
11. Oil seal ring
Coat the oil seal ring with ATF and install it to the output
shaft.
NOTE:
Do not spread the ring ends too much.
12. Output shaft
Install output shaft into rear planetary assembly.

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–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