Forward and Reverse Clutch Assemble

Tools Required

• DT 46451  (DW240-020) Brake/Clutch Spring Compressor. See Special Tools .
• DT 46452  (DW240-030) Forward Clutch Adapter. See Special Tools .
• DT 46520  (DW240-120) Measuring Terminal. See Special Tools .

Fig 1: O-Ring & Intermediate Shaft Sub-Assembly
Courtesy of GENERAL MOTORS CORP.
1. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install it to the intermediate shaft sub-assembly.
Fig 2: O-Ring & Forward Clutch Drum
Courtesy of GENERAL MOTORS CORP.
2. Coat a new O-ring (1) with ATF, and install it to the forward clutch drum.
Fig 3: Forward Clutch Drum, O-Ring, Lip Seal & ATF
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Do not damage the O-ring and lip seal of forward clutch drum.
3. Coat the forward clutch drum with ATF, install the forward clutch drum.
Fig 4: Forward Clutch Drum, Lip Seal & ATF
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Do not damage the lip seal of forward clutch return spring.
4. Coat the forward clutch piston with ATF, install the forward clutch piston.
Fig 5: Clutch Balancer & Forward Clutch Return Spring
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Do not damage the lip seal of forward clutch return spring.
5. Install the forward clutch return spring and clutch balancer.
Fig 6: Compressing Spring Using DT 46451 & DT 46452
Courtesy of GENERAL MOTORS CORP.
6. Place the DT 46451  (1) and DT 46452  (2) on the clutch balancer and compress the piston return spring. See Special Tools .
NOTE: Refer to Transaxle Case Damage Notice in Cautions and Notices.
IMPORTANT: Do not expand the snap ring excessively.
7. Using a snap ring expander, install the snap ring.
Fig 7: Flanges, Discs, Plate & Forward Clutch Drum
Courtesy of GENERAL MOTORS CORP.
8. Install the 3 plates (2), 3 discs (3), and the flange (1) in order 2-3-2-3-2-3-1.
Fig 8: Removing Forward/Reverse Clutch Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
9. Using a screwdriver, install the snap ring.
10. Check that the end gap of the snap ring is not aligned with one of the cutouts.
Fig 9: Flanges, Discs, Plate & Reverse Clutch Drum
Courtesy of GENERAL MOTORS CORP.
11. Install the plate (2), 2 discs (3), and 2 flanges (1) in order 1-3-2-3-1.
Fig 10: Removing/Installing Reverse Clutch Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
12. Using a screwdriver, install the snap ring.
13. Check that the end gap of the snap ring is not aligned with one of the cutouts.
Fig 11: Measuring Reverse Clutch Pack Clearance While Applying Compressed Air
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in Cautions and Notices.
14. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
15. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing 392 kPa (57 psi) of compressed air.
    • If the pack clearance is less than the limit of pack clearance, parts may have been assembled incorrectly, so check and reassemble again.

      If the pack clearance is non-standard, select another flange.

      Specifications:  The pack clearance is 0.4-1 mm (0.0157-0.0394 in).

    • There are 4 flanges in different thickness.

      Specifications: 

      • The number 1 flange thickness is 3 mm (0.118 in).
      • The number 2 flange thickness is 3.2 mm (0.126 in).
      • The number 3 flange thickness is 3.4 mm (0.134 in).
      • The number 4 flange thickness is 3.6 mm (0.142 in).

Fig 12: Measuring Forward Clutch Pack Clearance While Applying Compressed Air
Courtesy of GENERAL MOTORS CORP.
16. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
17. Using a dial indicator and the DT 46464  (1), measure the forward clutch pack clearance while applying and releasing 392 kPa (57 psi) of compressed air. See Special Tools .
    • The forward and reverse clutch will come out as you apply the compressed air. Therefore, while the checking is being done, press on the input shaft of the forward and reverse clutch using stamping machine or alike so that the pressure is not applied on the forward and reverse clutch.
    • If the pack clearance is less than the limit of pack clearance, parts may have been assembled incorrectly, so check and reassemble again.

      If the pack clearance is non-standard, select another flange.

      Specifications:  The pack clearance is 1.1-1.5 mm (0.043-0.059 in).

    • There are 4 flanges in different thickness.

      Specifications: 

      • The number 1 flange thickness is 3 mm (0.118 in).
      • The number 2 flange thickness is 3.2 mm (0.126 in).
      • The number 3 flange thickness is 3.4 mm (0.134 in).
      • The number 4 flange thickness is 3.6 mm (0.142 in).