1998 OPEL FRONTERA transmission

7A–194 AUTOMATIC TRANSMISSION (AW30-40LE)
252RY00008
252RY00004
247RY00020
252RY00009
23. Snap ring
Using snap ring pliers, install the snap ring as shown in the
figure.
Install and tighten the two bolts.
Check end of output shaft
Using a dial indicator, measure the end play of the output
shaft by hand.
24. Flange, plate and disc
Install the (flat ring) 4.0 mm (0.157 in.) thick flange with the
rounded edge side of the flange facing the disc.
Alternately install four discs and three plates. (Disc first)Nꞏm(kgꞏm / lbꞏft)
Torque 25 (2.6/19)
mm (in.)
End play0.27–0.86
(0.0106–0.0339)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–195
246RY00001
252RY00003
244RY00001
246RY00001
25. Snap ring
Install the (stepped ring) flange with the flat side of the
flange facing the disc.
Install the snap ring.
Check piston stroke of overdrive brake
Place a dial indicator onto the overdrive brake piston as
shown in the figure.
Measure the stroke by applying and releasing the
compressed air (4–8kg/cm
2, 57–114–psi or 392–785 kPa)
as shown in the figure.
If the values are nonstandard, select another flange.
Remove the snap ring. Snap ring (Reference) mm (in.)
Inside diameter 167.9 (6.61)
mm (in.)
Piston stroke1.40–1.70
(0.0551–0.0670)
Available Flange size mm(in.)
3.3 (0.130) 3.8 (0.150)
3.5 (0.138) 3.9 (0.154)
3.6 (0.142) 4.0 (0.158)
3.7 (0.146)

7A–196 AUTOMATIC TRANSMISSION (AW30-40LE)
246RY00026
252RY00010
252RY00002
252RY00011
Remove two flanges, three plates and four discs.
26. Bearing and race
Coat the bearing and races with petroleum jelly and install
them onto the overdrive support.
27. OD planetary ring gear
Install the overdrive planetary ring gear.
28. Bearing and race
Coat the bearing and race with petroleum jelly and install
them onto the planetary ring gear. Bearing and races diameter (Reference) mm (in.)
Inside Outside
Bearing 36.5 (1.437) 48.5 (1.910)
Race (Front) 37.2 (1.465) 58.8 (2.315)
Race (Rear) 33.7 (1.327) 50.1 (1.973)
Bearing and race diameter (Reference) mm (in.)
Inside Outside
Bearing 26.0 (1.024) 46.8 (1.843)
Race 24.2 (0.953) 47.8 (1.882)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–197
252L100017
252L100001
252L100018
252RY00009
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)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–199
REASSEMBLY OF MAJOR COMPONENTS (2)
242RY00006
Reassembly steps
1. Second brake drum gasket
2. Accumulator piston
3. Check valve, spring
4. Valve body
5. Solenoid wiring
6. Oil strainer assembly
7. Oil pan

7A–200 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00013
240RY00014
240RY00027
Important operations
1. Second brake drum gasket
Install a new brake drum gasket to the transmission case.
Individual piston operation inspection
Check for the sound of operation while injecting
compressed air into the oil hole indicated in the figure.
NOTE:
When inspecting the direct clutch, check with the C–0
accumulator piston hole closed. If there is no noise,
disassemble and check the condition of the parts.
A : C–0 Accumulator piston hole
2. Accumulator piston
Coat the O–ring with ATF and install it to the piston.
Install the five springs and four accumulator pistons to the
bore as shown in the figure. 1: OD direct clutch 5: Second coast brake
2: Direct clutch 6. Second brake
3: Forward clutch 7. First and reverse brake
4: OD brake

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–201
240RY00015
240RY00029
240RY00010
240RY00016
3. Check valve, spring
Install new check valve and spring.mm (in.)
Piston Outer diameter Height
B–2 36.8 (1.449) 62.5 (2.461)
C–2 36.8 (1.449) 56.6 (2.228)
B–0 31.8 (1.252) 52.0 (2.047)
C–0 29.8 (1.173) 44.0 (1.732)
Spring Free length Outer diameter
(1) B–2 75.8 (2.984) 20.1 (0.791)
(2) C–2 (Inner) 42.1 (1.658) 14.7 (0.579)
(3) C–2 (Outer) 64.0 (2.520) 20.2 (0.795)
(4) B–0 63.6 (2.504) 16.0 (0.630)
(5) C–0(Outer) 74.6 (2.937) 20.9 (0.823)
(6) C–0(Inner) 46.0 (1.811) 14.0 (0.551)