Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.

Use a J 7872 in order to measure the direct clutch piston stroke before disassembly.
1. 1.1. Temporarily install the direct clutch assembly onto the fluid pump (2) and place the J 7872 plunger on the direct clutch piston (1).
2. 1.2. Apply 392-785 kPa (57-114 psi) of compressed air into the direct clutch apply passage of the fluid pump and observe the J 7872 .
3. 1.3. The standard direct clutch piston stroke is greater or less than specified, inspect all direct clutch components for excessive wear.
4. 1.4. Standard direct clutch piston stroke 1.12-1.52 mm (0.0441-0.0598 in).
Fig 1: Checking Direct Clutch Piston Stroke Using J 7872
Courtesy of GENERAL MOTORS CORP.
Remove the direct clutch snap ring (1) from the direct clutch drum (2).

Fig 2: Removing Direct Clutch Snap Ring
Courtesy of GENERAL MOTORS CORP.
Remove the direct clutch assembly (1) from the forward clutch assembly (2).

Fig 3: Removing Direct Clutch Assembly
Courtesy of GENERAL MOTORS CORP.
Remove the forward clutch inner thrust bearing (4) from the center of the forward clutch drum.
Remove the direct clutch thrust washer (2) from the top of the forward clutch assembly (3).
Remove the forward clutch outer thrust bearing (1) from the top of the forward clutch drum.

Fig 4: Removing Forward Clutch Inner Thrust Bearing, Outer Thrust Bearing & Direct Clutch Thrust Washer
Courtesy of GENERAL MOTORS CORP.
Remove the following components from the direct clutch drum (1):
- The direct clutch flange
- 3 discs
- 3 plates
Fig 5: Removing Direct Clutch Flange, Discs & Plates
Courtesy of GENERAL MOTORS CORP.
Use a J 23327 and a hydraulic press in order to remove the direct clutch piston return spring snap ring (1) from the direct clutch piston return spring retainer.

Fig 6: Removing Direct Clutch Piston Return Spring Snap Ring
Courtesy of GENERAL MOTORS CORP.
Remove the direct clutch piston return springs (2) from the direct clutch piston (1).

Fig 7: Removing Direct Clutch Piston Return Springs
Courtesy of GENERAL MOTORS CORP.

Important: When using compressed air to remove components, air pressure should not exceed 98 kPa (14 psi).
Remove the direct clutch piston (1) from the direct clutch drum by temporarily installing the direct clutch assembly onto the fluid pump (2). Apply low pressure compressed air into the direct clutch apply passage of the fluid pump.
Remove the direct clutch piston seals from the direct clutch piston.
Clean all the direct clutch components and dry the components thoroughly.
Inspect the direct clutch discs for excessive wear or damage. Replace the components as necessary.
Inspect the direct piston for cracks or porosity and replace as necessary.

Fig 8: Removing Direct Clutch Piston Using Compressed Air
Courtesy of GENERAL MOTORS CORP.
Inspect the direct clutch piston check ball (2) operation by applying compressed air into the working and release sides of the direct clutch piston (1, 3). There must be no air leakage on the working side. Air must pass freely through the release side. If these conditions do not exist, replace the direct clutch piston.
Inspect the direct clutch piston return spring for distortion or weakness and replace as necessary.

Fig 9: Inspecting Direct Clutch Piston Check Ball Using Compressed Air
Courtesy of GENERAL MOTORS CORP.
Use the J 26900-6 in order to measure the inside diameter of the direct clutch bushing (1).
- The maximum inside diameter of the direct clutch bushing is 48.270 mm (1.9004 in)
- If the inside diameter of the direct clutch house bushing is greater than specified, replace the direct clutch drum
Fig 10: Measuring Inside Diameter Of Direct Clutch Bushing Using J 26900-6
Courtesy of GENERAL MOTORS CORP.