Installation 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.

CAUTION: Refer to SAFETY GLASSES CAUTION in Cautions and Notices.

NOTE: When installing new clutch discs in the 1st - reverse brake, forward clutch or direct clutch assemblies, the new clutch discs MUST be soaked in Dexron® - III automatic transmission fluid GM P/N 12341643, or equivalent, two hours prior to installation. This causes the clutch material on the discs to permeate with fluid which will aid in ease of assembly and prevent clutch overheating on first time engagement.

Important: When using compressed air to remove components, air pressure should not exceed 98 kPa (14 psi).

Install the two underdrive clutch piston seals (1) onto the underdrive clutch piston (2).

Fig 1: Installing Underdrive Clutch Piston Seals
Courtesy of GENERAL MOTORS CORP.
Apply J 36850 to the new underdrive clutch piston seals.
Install the underdrive clutch piston (1) into the underdrive clutch drum (2).
Install the underdrive clutch piston return spring and the underdrive clutch piston return spring into the underdrive clutch piston.

Fig 2: Installing Underdrive Clutch Piston
Courtesy of GENERAL MOTORS CORP.
Use a J 23327 with a J 37279 to install the underdrive clutch piston return spring snap ring onto the underdrive piston return spring (2).

Fig 3: Installing Underdrive Clutch Piston Return Spring Snap Ring
Courtesy of GENERAL MOTORS CORP.
Install the 4 discs, 4 plates and underdrive clutch flange into the underdrive clutch drum (1) in the following order:
- 1 plate
- 1 disc
- 1 plate
- 1 disc
- 1 plate
- 1 disc
- 1 plate
- 1 disc
Fig 4: Installing Underdrive Clutch Flange, Discs, & Plates
Courtesy of GENERAL MOTORS CORP.

Important: The underdrive clutch flange must be installed with the flat side facing down and the stepped portion facing upwards.
Install the flange.
Install the underdrive clutch snap ring into the underdrive clutch drum.
Install the underdrive one-way clutch sprag assembly (3) and retainers (2, 4) into the underdrive one-way clutch outer race (5).

Fig 5: Installing Underdrive One-Way Clutch Sprag Assembly & Retainers
Courtesy of GENERAL MOTORS CORP.
Install the rear thrust plate (2) onto the underdrive one-way clutch outer race (1).

Fig 6: Installing Rear Thrust Plate Onto Underdrive One-Way Clutch Outer Race
Courtesy of GENERAL MOTORS CORP.
Use a J 7872 to measure the underdrive clutch piston stroke after assembly.
Place the underdrive clutch drum (1) on the underdrive clutch drum support in the transaxle case and the J 7872 plunger on the underdrive clutch piston.

Fig 7: View Of J 7872 On Underdrive Clutch Piston
Courtesy of GENERAL MOTORS CORP.
Apply 392 to 785 kPa (57 to 114 psi) of compressed air into the underdrive clutch apply passage (1) in the transaxle case and observe the J 7872 .
- The standard underdrive clutch piston stroke should fall within 1.500 to 1.900 mm (0.0590 to 0.0748 in).
  
  Fig 8: Measuring Underdrive Clutch Piston Stroke Using J 7872
  Courtesy of GENERAL MOTORS CORP.
- If the underdrive clutch piston stroke does not fall within specification, select one of the two following underdrive clutch flange sizes to bring the underdrive clutch piston stroke within specification:
  - 2.040 mm (0.0803 in)
  - 2.400 mm (0.0945 in)
- Remove the old underdrive clutch drum support seal rings from the underdrive clutch drum support.
Inspect the underdrive one-way clutch after assembly by placing the underdrive one-way clutch onto the rear of the underdrive clutch drum, holding the underdrive clutch drum stationary and rotating the underdrive one-way clutch.
- The underdrive one-way clutch (1) should turn freely in a counterclockwise direction (2) and should not turn in a clockwise direction (3).
  
  Fig 9: Checking Underdrive One-Way Clutch Rotation
  Courtesy of GENERAL MOTORS CORP.
- If the underdrive one-way clutch is installed correctly on the underdrive clutch drum and the underdrive one-way clutch can be turned clockwise, replace the underdrive one-way clutch.