Opel Frontera UBS. Manual - part 2501

7A–54

AUTOMATIC TRANSMISSION (4L30–E)

24. Install retainer and spring assembly (22) into fourth

clutch piston (21).

25. Install snap ring (23) in adapter case.

D

Install 5–8840–0195–0 (J–23327) and
5–8840–2263–0 (J–23327–90) fourth clutch spring
compressor.

D

Seat snap ring in groove.

D

Remove compressor.

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26. Install selective washer using petroleum jelly.
27. Install two O–ring seals (24) in main case and adapter

case/main case seal ring (25).

28. Install 5–8840–2268–0 (J–38588) guide pins.

D

Install adapter case and center support assembly to
main case.

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29. Install thrust washer (26) into adapter case, with

tangs pointing downwards.

30. Preassemble overdrive internal gear (27) and thrust

bearing assembly (28) onto the turbine shaft and
overrun clutch assembly.

NOTE: Install  bearing assembly, black side up.  Use
petroleum jelly to keep assembly in place.

31. Install overdrive carrier (30) and internal gear

assembly into adapter case.

32. Install fourth clutch plates (29) in the following order:

Steel, Lined, Steel, Steel, Lined, Steel.  Steel plates
go in with short tang facing towards valve body
surface. 

7A–55

AUTOMATIC TRANSMISSION (4L30–E)

33. Install fourth clutch retainer (31) with the notch facing

up and positioned towards valve body surface.

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34. Overdrive clutch end play measurement

1. Install the 5–8840–2262–0 (J–23085–A)

selective washer gauging tool on the adapter
case flange and against the input shaft.

2. Position the inner shaft of the tool against the

thrust surface of the overrun clutch housing.

3. Tighten thumb screw.  Remove the tool.

4. Measure gap.  Select appropriate size washer as

shown in the chart.

5. Set selective thrust washer aside.

Selective Thrust Washer

Gap:  mm(in)

Color

1.53 – 1.63 (0.060 – 0.064)

Yellow

1.72 – 1.82 (0.068 – 0.072)

Red

1.91 – 2.01 (0.075 – 0.079)

Black

2.10 – 2.20 (0.083 – 0.087)

Natural

2.29 – 2.39 (0.090 – 0.094)

Green

2.48 – 2.58 (0.098 – 0.102)

Blue

FOLLOWING THE PROCEDURE SHOULD
RESULT IN FINAL END–PLAY FROM 0.1 mm TO
0.8 mm (0.004 in TO 0.03 in)

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35. Install selective washer (32).

NOTE: Use petroleum jelly to hold selective washer in
place.

36. Install gasket (33).
37. Install converter housing and oil pump assembly (34)

to adapter case.

D

Fit and tighten seven outer 13 mm screws.

Torque: 39 N

•

m (4.0 kg·m/29 lb ft)

7A–56

AUTOMATIC TRANSMISSION (4L30–E)

D

Ensure free rotation of pump using 5–8840–2273–0
(J–23082–01) oil pump rotation tool.

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38. Overdrive clutch end play measurement.

1. Fit 5–8840–2271–0 (J–25022) and

5–8840–0618–0 (J–24773–1) turbine shaft puller
on turbine shaft.

2. Position axial play checking tool on converter

housing mating face.

3. Pull turbine shaft upwards with puller until first

resistance is met. (due to weight of overdrive
assembly).

4. Maintain shaft in this position and set indicator to

zero.

5. Pull turbine shaft further upwards with puller.

Read end play shown on indicator.

End play:  0.1mm – 0.8mm (0.004 in – 0.031in)

6. Remove axial play checking tool and puller.

NOTE: If end play is not correct, repeat selective washer
selection.

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39. Inspect extension housing oil seal and replace if

necessary, using 5–8840–2282–0 (J–36797)
extension housing oil seal installer.

D

Rotate transmission to horizontal position, with
valve body side down.

D

Inspect parking wheel seal ring.  Replace if
necessary.

D

Install wheel parking lock assembly (35).

40. Install speed wheel (36) and snap ring (37).

NOTE: Use extra long, needle-nose pliers.

41. Install gasket onto extension assembly with a thin

coating of oil.

D

Install extension housing assembly (38), and align
parking pawl shaft.

D

Install actuator assembly into extension assembly.

D

Install seven 8 mm hexagon socket head screws.

Torque: 32 N

•

m (3.3 kg·m/24 lb ft)

42. Inspect speed sensor O–ring.  Replace if necessary.

D

Install speed sensor assembly (39) and 10 mm
screw. 

Torque: 9 N

•

m (0.9 kg·m/78 lb in)

7A–57

AUTOMATIC TRANSMISSION (4L30–E)

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43. Main case end play measurement.

1. Attach axial play checking tool on the extension

housing and set indicator to zero on output shaft.

2. Manually push output shaft upwards.

End play:  0.36mm – 0.80mm (0.014 in – 0.031in)

3. Remove axial play checking tool.

4. If end play is not correct, repeat selective washer

selection.

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44. Inspect servo piston seal ring.  Replace if necessary.

D

Ensure brake band is correctly positioned.  Rotate
output shaft if necessary.

D

Install 5–8840–2274–0 (J–38428) servo piston
fitter in servo bore.

D

Install apply rod (40), round end toward band, return
spring (41) and piston assembly (42).

45. Install the 5–8840–0501–0 (J–23075) servo spring

compressor with offset to rear of case.

D

Compress servo piston seal ring, using fitter while
tightening the tool screw.

D

Install servo piston retaining ring (43).

D

Remove tool.

D

Adjust the brake band by tightening the servo
adjusting screw to 4.5 N·m torque.  Be certain the
lock nut is loose, then back–off the screw five turns
exactly. Hold piston sleeve with wrench and tighten
lock nut to 18.5 N·m torque. Be certain the adjusting
screw does not turn.