Opel Frontera UBS. Manual - part 545

7A–49

AUTOMATIC TRANSMISSION (4L30–E)

NOTE: Use  petroleum jelly to hold the washer and
bearing in place.

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16. Carefully align the second clutch plate inner tangs.

D

Install thrust washer, tangs pointing downward, and
locating tang positioned in slot on second clutch
hub.

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

17. Install third clutch and intermediate shaft assembly

(13) into the second clutch drum (14).

18. Install second and third clutch assemblies into the

main case.  Twist output shaft and clutch assemblies
to ensure proper fit.

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19. Install pressure plate (15) with lip side up, tang facing

valve body face.

20. Install reverse clutch plates. Start with a steel plate

(17) and alternate with a lined plate (16).

21. Install waved clutch plate (18) with center tang facing

valve body side.

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7A–50

AUTOMATIC TRANSMISSION (4L30–E)

22. Second clutch end play measurement

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

Selective washer gauging tool (with spacer ring)
on the case flange and against the intermediate
shaft.

2. Position the inner shaft of the gauging tool against

the thrust surface of the second clutch hub.

3. Tighten thumb screw.  Remove the tool.

4. Fit the spacer ring on the inner shaft of the tool.

5. Measure the gap, and select the appropriate

washer as shown in the chart.

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 RE-
SULT IN FINAL END–PLAY FROM 0.36 mm TO
0.79 mm (0.014 in TO 0.031 in)

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23. Inspect fourth clutch piston seals and replace if

necessary.

D

Lubricate 5–8840–2267–0 (J–38554) fourth clutch
piston fitter and install it on fourth clutch piston (19).

D

Install fourth clutch piston (19) in adapter case (20).

D

Remove fitter.

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

clutch piston (21).

7A–51

AUTOMATIC TRANSMISSION (4L30–E)

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–52

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 RE-
SULT 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)