1998 OPEL FRONTERA transmission

7A–114 AUTOMATIC TRANSMISSION (AW30-40LE)
OD PLANETARY GEAR AND OD DIRECT CLUTCH ASSEMBLY (C-0)
DISASSEMBLY
252L100002
Disassembly steps
1. OD direct clutch assembly
2. Thrust bearing
3. Snap ring
4. Flange, disc and plate
5. Snap ring
6. Piston retur n spring
7. OD direct clutch piston with O-ring
8. O-ring
9. Thrust bearing
10. Snap ring
11. Ring gear flange
12. Race
13. Snap ring
14. Retaining plate
15. OD one-way clutch
16. Thrust washer

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–115
252L100003
252L100004
252L100005
252L100016
Important operations
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
1. OD direct clutch assembly
Remove OD direct clutch assembly from OD planetary
gear.
2. Thrust bearing
Then remove thrust bearing with the race from OD direct
clutch drum.
Check piston stroke of OD direct clutch (C-O)
Place the oil pump onto the torque conver ter, and then
place the OD direct clutch assembly onto the oil pump.
Use a dial indicator, measure the OD direct clutch piston
stroke applying and releasing the compressed air (4– 8 kg/
cm
2, 57– 114 psi, 392– 785 kPa) as shown.
mm (in.)
Piston stroke1.85– 2.15
(0.0728– 0.0847)

7A–116 AUTOMATIC TRANSMISSION (AW30-40LE)
252L100006
252L100007
252L100008
252ry00021
3. Snap ring
Remove snap ring from clutch drum.
4. Flange, disc and plate
Remove flange, two discs and two plates.
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: 5-8840-0195-0 (J-23327-1)
6. Piston return spring
Remove piston return spring.
7. OD direct clutch piston with O-ring
Place the oil pump onto the torque converter and then
place the OD direct clutch onto the oil pump.
Holding the OD direct clutch piston by hand, apply
compressed air to the oil pump to remove the OD direct
clutch piston.
Remove the OD direct clutch piston.
8. O-ring
Remove two O-rings from piston.
9. Thrust bearing
Remove bearing and race from OD planetary ring gear.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–117
252RY00022
252RY00023
252RY00024
252RY00025
10. Snap ring
Remove snap ring.
11. Ring gear flange
Remove ring flange from OD planetary ring gear.
13. Snap ring
Remove snap ring, using screwdriver.
14. Retaining plate
Remove retaining plate from OD planetary gear.

7A–118 AUTOMATIC TRANSMISSION (AW30-40LE)
252RY00026
252RY00027
252RY00028
252RY00029
15. OD one-way clutch
Remove OD one-way clutch with outer race.
INSPECTION AND REPAIR
Check discs
Using a micrometer, measure the thickness of the discs.
If the thickness is less than the minimum, replace the disc.
Check piston return spring
Using calipers, measure the free length of the return spring.
Check OD 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.)
Minimum thickness 1.84 (0.0724)
mm (in.)
Standard length 15.8 (0.622)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–119
252L100009
252RY00031
Check OD direct clutch drum bushings
Using a dial indicator, measure the inside diameter of the
clutch drum bushings.
If the inside diameter is greater than the maximum, replace
the clutch drum.
Check OD planetary gear bushing
Using a dial indicator, measure the inside diameter of the
planetary gear bushing.
If the inside diameter is greater than the maximum, replace
the planetary gear.mm (in.)
Maximum inside diameter 27.11 (1.0673)
mm (in.)
Maximum inside diameter 11.27 (0.4437)

7A–120 AUTOMATIC TRANSMISSION (AW30-40LE)
REASSEMBLY
252L100010
Reassembly steps
1. Thrust washer
2. OD one-way clutch
3. Retaining plate
4. Snap ring
5. Race
6. Ring gear flange
7. Snap ring
8. Thrust bearing
9. O-ring
10. OD direct clutch piston with O-ring
11. Piston return spring
12. Snap ring
13. Flange, disc and plate
14. Snap ring
15. Thrust bearing
16. OD direct clutch assembly

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–121
252RY00032
252RY00033
252RY00026
252RY00024
Important operations
1. Thrust washer
Install the thrust washer to the OD planetary gear, facing
the grooved side upward.
2. OD one-way clutch
Install the one-way clutch into the outer race, with the
flanged side of the one-way clutch facing upward.
Install OD one-way clutch with outer race to overdrive
planetary gear.
3. Retaining plate
4. Snap ring
Install retaining plate, then install snap ring, using a
screwdriver.