Opel Frontera UBS. Manual - part 2569

AUTOMATIC TRANSMISSION (AW30-40LE)

7A–139

248RY00035

248RY00036

248RY00029

248RY00061

6. Flange

Install the flange, with the flat side facing downward.

7. Snap ring

Install the snap ring with a screwdriver. Be sure the end
gap of the snap ring is not aligned with the cutout portion of
the direct clutch drum.

Check piston stroke of direct clutch (C-2)

Place the direct clutch assembly onto the OD support
assembly.

Using a dial indicator, measure the direct clutch piston
stroke by applying and releasing compressed air (4– 8 kg/
cm

2

, 57– 114 psi or 392– 785 kPa) as shown.

If the piston stroke is not within specification, replace the
discs and recheck the piston stroke.
If the piston stroke is non standard, select another flange.
There are eight flanges.

mm (in.)

Piston stroke

1.6– 1.9

(0.0630– 0.0748)

mm (in.)

No.

Flange thickness

No.

Flange thickness

33

3.3 (0.130)

37

3.7 (0.146)

34

3.4 (0.134)

38

3.8 (0.150)

35

3.5 (0.138)

39

3.9 (0.154)

36

3.6 (0.142)

40

4.0 (0.158)

7A–140

AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00037

248RY00038

8. Clutch drum thrust washer (plastic)

Coat the thrust washer with petroleum jelly and install it onto
the direct clutch.

NOTE:  
Make sure that the lugs fit into the cutout portions on the
direct clutch.

Install direct clutch  assembly

Align the flukes of discs in the direct clutch.
Install the direct clutch assembly onto the forward clutch
assembly.
Check that the distance from the direct clutch end to the
forward clutch end is 71.2 mm (2.803 in.).

AUTOMATIC TRANSMISSION (AW30-40LE)

7A–141

FORWARD CLUTCH ASSEMBLY (C-1)

DISASSEMBLY

248RY00063

Disassembly steps

▲

 1. Thrust bearing

2. Race

▲

 3. Snap ring

4. Flange

5. Disc and plate

▲

 6. Snap ring

7. Piston return spring

▲

 8. Piston

9. O-ring

10. O-ring

11. Oil seal ring

12. Thrust bearing

7A–142

AUTOMATIC TRANSMISSION (AW30-40LE)

248RY00039

248RY00048

248RY00040

248RY00041

Important operations

Remove forward clutch assembly from direct clutch
assembly.

1. Thrust bearing

Place wooden blocks, etc, to prevent forward clutch shaft
from touching the work stand, and place the OD support on
them.
Place the forward clutch onto the OD support and remove
the bearing and race.

Check piston stroke of forward clutch (C–1)

Using a dial indicator, measure the forward clutch piston
stroke by applying and releasing compressed air (4–8kg/
cm

2

, 57–114psi or 392–785kPa)as shown.

3. Snap ring

Remove snap ring from clutch drum.

mm (in.)

Pack clearance

0.6–1.0 (0.0236–0.0394)