Opel Frontera UBS. Manual - part 1476

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 portion 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 clearance

0.6–1.0

(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)