1998 OPEL FRONTERA clutch

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–185
22. OD suppor t
23. Snap ring
24. Flange, plate and disc
25. Snap ring
26. Bearing and race
27. OD planetary ring gear
28. Bearing and race
29. Race
30. OD planetary gear and OD direct clutch
31. Bearing
32. Race
33. Oil pump

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–187
248RY00016
246RY00004
247RY00011
246RY00005
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)
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)

7A–190 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00021
248RY00022
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247RY00015
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)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–191
247RY00016
247RY00017
247RY00019
247RY00018
Align the flukes of the discs in the forward clutch.
16. Front planetary ring gear
Align the spline of th front planetary gear with the flukes of
the discs and install the front planetary gear to the forward
clutch.
17. Bearing and race
Coat the bearing and race with petroleum jelly and install
them onto the ring gear.
18. Direct clutch and forward clutch
Install the assembled direct clutch, forward clutch and front
planetary ring gear into the transmission case. Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing 32.6 (1.283) 47.7 (1.878)
Race 30.6 (1.205) 53.6 (2.110)

7A–192 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00024
248RY00025
248RY00026
248RY00027
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)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–197
252L100017
252L100001
252L100018
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29. Race
Coat the race with petroleum jelly and install it onto the
planetary gear.
30.OD planetary gear and OD direct clutch
Install the overdrive planetary gear and direct clutch.
31.Bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the direct clutch.
Install the (flat ring) 4.0mm (0.157 in.) thick flange with the
rounded edge side of the flange facing the disc.
Alternately install three discs and two plates. (Disc first) Race diameter (Reference) mm (in.)
Inside Outside
Race 27.3 (1.075) 41.8 (1.646)
Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing and
race28.9 (1.138) 50.2 (1.976)

7A–198 AUTOMATIC TRANSMISSION (AW30-40LE)
246RY00001
252RY00014
241RY00003
Install the (stepped ring) flange with the flat side of the
flange facing the disc.
Install the snap ring.
32.Race
Coat the race with petroleum jelly and install it onto the oil
pump.
33.Oil pump
Coat the O–ring with ATF and install it around the pump
body.
Place the oil pump through the input shaft, and align the
bolt holes of the pump body with the transmission case.
Hold the input shaft, and lightly press the oil pump body to
slide the oil seal rings on the stator shaft through the direct
clutch drum.
NOTE:
Do not push on the oil pump strongly or the oil seal ring
will stick to the direct clutch drum.
Install the seven bolts.
Check input shaft rotation
Make sure the input shaft rotates smoothly. Race diameter (Reference) mm (in.)
Inside Outside
Race 28.1 (1.106) 47.3 (1.862)
Nꞏm(kgꞏm / lbꞏft)
Torque 22 (2.2/16)