1998 OPEL FRONTERA transmission

7A–146 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00044
248RY00046
248RY00047
248RY00049
Important operations
1. Thrust bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the forward clutch drum, with the race
side facing downward.
2. Oil seal ring
Coat the three oil rings with ATF.
Contract the oil seal rings as shown, and install three oil
seal rings onto the forward clutch drum.
NOTE:
Do not spread the ring ends more than necessary.
3. O-ring
Coat a new O-ring with ATF and install O-ring on the
forward clutch drum.
4. O-ring
Coat new O-rings with ATF and install two O-rings on the
forward clutch piston.
5. Forward clutch piston
Being careful not to damage the O-rings, press the forward
clutch piston into the forward clutch drum. Assembled bearing and race (Reference) mm (in.)
Inside diameter 33.7 (1.327)
Outside diameter 47.8 (1.882)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–147
248RY00065
248RY00003
248RY00069
248RY00070
6. Piston return spring
Install piston return spring.
7. Snap ring
Place special tool on the spring retainer, and compress the
return spring.
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.
8. Cushion plate
Install cushion plate rounded side down as shown.
9. Disc and plate
Install discs. plates and flange.
Install in order:P–D–P–D–P–D–P–D–P–D–P–D
10. Flange
And then install the flange, with the rounded edge facing
downward.

7A–148 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00041
248RY00040
248RY00048
11. Snap ring
Install the snap ring with a screw driver. Be sure the end
gap of the snap ring is not aligned with the cutout por tion of
the forward clutch drum.
Check piston stroke of forward clutch (C–1)
Using a dial indicator, measure the forward clutch piston
stroke by applying and releasing the compressed air (4–
8kg/cm
2, 57–114psi or 392–785kPa) as shown.
If the Pack clearance is not within specification, select
another flange, and recheck the piston stroke.
There are eight flanges.
12. Race
13. Thrust bearing
Coat the race and bearing with petroleum jelly, and install
them onto the forward clutch drum. mm(in.)
Pack clearance0.6–1.0
(0.0236–0.0394)
mm (in.)
No. Flange thickness No. Flange thickness
61 3.0 (0.118) 92 3.4 (0.134)
63 4.2 (0.165) 93 3.6 (0.142)
64 4.4 (0.173) 94 3.8 (0.150)
91 3.2 (0.126) 95 4.0 (0.158)
Race and bearing diameter (Reference) mm(in.)
Inside Outside
Race 26.0 (1.024) 48.9 (1.925)
Bearing 26.0 (1.024) 46.7 (1.839)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–149
248RY00039
248RY00038
Install direct clutch assembly to forward clutch assembly
Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward clutch
assembly.
Check that distance from the direct clutch end to the forward
clutch end is 71.2 mm (2.803 in.).
mm (in.)
71.2 (2.803)

7A–150 AUTOMATIC TRANSMISSION (AW30-40LE)
FRONT PLANETARY GEAR
DISASSEMBLY
247RY00022
247RY00021
INSPECTION AND REPAIR
Check front planetary ring gear bushing
Using a dial indicator, measure the inside diameter of
the planetary ring gear bushing.
If the inside diameter is greater than the maximum,
replace the planetary ring gear.
Disassembly steps
1. Race
2. Thrust bearing
3. Race
4. Front planetary gear
5. Race (Metal)
6. Thrust bearing
7. Race
mm (in.)
Maximum inside diameter 24.08 (0.9480)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–151
REASSEMBLY
247RY00045
Reassembly steps
1. Thrust bearing and race
2. Race (Metal)
3. Thrust bearing and race
4. Race

7A–152 AUTOMATIC TRANSMISSION (AW30-40LE)
247RY00023
247RY00024
247RY00025
247RY00026
Important operations
1. Thrust bearing and race
Coat the races and bearing with petroleum jelly.
Install the race and bearing to the rear side of the planetary
gear.
2. Race (Metal)
Turn over the planetary gear and install the race.
Make sure that the lugs fit into the holes on the planetary
gear.
3. Thrust bearing and race
Coat the races and bearing with petroleum jelly.
Install the race and bearing onto the rear side of the
planetary ring gear.
4. Race
Turn over the planetary ring gear and install the race onto
the front side of the planetary ring gear.mm (in.)
Inside Outside
Bearing 35.6 (1.402) 47.7 (1.878)
Race 33.7 (1.327) 47.6 (1.874)
Bearing and races diameter (Reference) mm (in.)
Inside Outside
Race 34.3 (1.350) 47.8 (1.882)
mm (in.)
Inside Outside
Race 30.6 (1.205) 53.6 (2.110)
Bearing 32.7 (1.287) 47.7 (1.878)
Races and bearing diameter (Reference) mm (in.)
Inside Outside
Race 26.8 (1.055) 47.0 (1.850)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–153
PLANETARY SUN GEAR AND NO.1 ONE–WAY CLUTCH
DISASSEMBLY
248RY00050
Disassembly steps
1. One–way clutch and second brake hub
2. Thrust washer (Plastic)
3. Oil seal ring (Metal)
4. Snap ring
5. Snap ring