1998 OPEL FRONTERA automatic transmission

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–175
246RY00018
246RY00019
246RY00020
246RY00021
Important operations
1. O–ring
Coat three new O–rings with ATF.
Install the two O–ring on the No.1 piston.
2. O–ring
Install the O–ring on the reaction sleeve.
3. 1st and reverse brake piston No.1
Install the No.1 piston to the reaction sleeve.
4. O–ring
Coat a new O–ring with ATF and install it on the No.2
piston.
5. Reaction sleeve
Install the No.1 piston with reaction sleeve onto the No.2
piston.
6. 1st reverse brake piston No.2
Align the teeth of the No.2 piston into the proper grooves.
Being careful not to damage the O–rings, press in the No.2
with No.1 first and reverse brake pistons into the
transmission case.
7. Return spring
Place piston return spring onto No.2 piston.

7A–176 AUTOMATIC TRANSMISSION (AW30-40LE)
247RY00002
246RY00022
247RY00043
8. Snap ring
Set special tool as shown, and compress the return spring
with special tool.
Spring compressor : 5–8840–0254–0 (J–25048)
Install the snap ring with snap ring pliers. Be sure the end
gap of the snap ring is not aligned with the spring retainer
claw.
Check first and reverse brake piston
Make sure the first and reverse brake piston moves
smoothly when applying and releasing the compressed air
into the transmission case.
9. Thrust bearing and race
Coat the assembled bearing and race with petroleum jelly.
Install the assembled bearing and race facing the bearing
side upward.
Assembled bearing and race
diameter. (Reference) mm (in.)
Inside diameter 39.2 (1.543)
Outside diameter 57.7 (2.272)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–177
TRANSMISSION CASE
DISASSEMBLY
249RY00001
Disassembly steps
1. Spacer
2. Pin
3. Manual valve lever shaft
4. Manual valve lever
5. Oil seal
6. Oil seal

7A–178 AUTOMATIC TRANSMISSION (AW30-40LE)
249RY00002
249RY00003
249RY00004
240RY00021
Important operations
1. Spacer
Using a chisel, cut off the spacer and remover it from the
shaft.
2. Pin
Using a punch, drive out the pin.
3. Manual valve lever shaft
4. Manual valve lever
Pull the manual valve lever shaft out through the case by
the threads.
5. Oil seal
6. Oil seal
Using a screwdriver, remove the oil seal.
On–vehicle replacement of oil seal
Using special tool, install the oil seal.
Installer : 5–8840–2169–0 (J–37232–2)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–179
REASSEMBLY
249RX00001
Reassembly steps
1. Oil seal
2. Oil seal
3. Spacer
4. Manual valve lever
5. Manual valve lever shaft
6. Pin

7A–180 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00021
249RY00005
249RY00006
249RY00003
Important operations
1. Oil seal
2. Oil seal
Coat a new oil seal lip with multi purpose grease.
Using special tool, drive in the oil seal.
Oil seal installer : 5–8840–2169–0 (J–37232–2)
3. Spacer
4. Manual valve lever
Assemble a new spacer to the manual valve lever.
5. Manual valve lever shaft
Install the manual valve lever shaft to the transmission case
through the manual valve lever by the threads.
6. Pin
Drive in the pin with the slot at a right angle to the shaft.
Match the spacer hole to the lever staking hollow and stake
the spacer to the lever.
Make sure the manual valve lever shaft turns smoothly.

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.