Forward and Reverse Clutch Disassemble

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: 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.
1. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
2. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing 392 kPa (57 psi) of compressed air.

   If the stroke is non-standard, inspect the discs, plates, and flange.

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

Fig 2: Measuring Forward Clutch Pack Clearance While Applying Compressed Air
Courtesy of GENERAL MOTORS CORP.
3. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
4. Using a dial indicator and the DT 46520  (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 stroke is non-standard, inspect the discs, plates and flange.

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

Fig 3: Removing/Installing Reverse Clutch Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
5. Using a screwdriver, remove the reverse clutch snap ring.
Fig 4: Flanges, Discs, Plate & Reverse Clutch Drum
Courtesy of GENERAL MOTORS CORP.
6. Remove the 2 flanges (1), the 2 discs (3), and the plate (2) from the reverse clutch drum.
Fig 5: Removing Forward/Reverse Clutch Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
7. Using a screwdriver, remove the snap ring.
Fig 6: Flanges, Discs, Plate & Forward Clutch Drum
Courtesy of GENERAL MOTORS CORP.
8. Remove the flange (1), 3 discs (3), and 3 plates (2) from the forward clutch drum.
Fig 7: Compressing Spring Using DT 46451 & DT 46452
Courtesy of GENERAL MOTORS CORP.
9. Using the DT 46451  (1) and the DT 46452  (2), compress the spring. See Special Tools .
NOTE: Refer to Transaxle Case Damage Notice in Cautions and Notices.
IMPORTANT: Do not expand the snap ring excessively.
10. Using a snap ring expander, remove the snap ring.
Fig 8: Clutch Balancer & Forward Clutch Return Spring
Courtesy of GENERAL MOTORS CORP.
11. Remove the clutch balancer and forward clutch return spring.
Fig 9: Forward/Reverse Multiple Disc Clutch & Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
12. Install the forward and reverse multiple disc clutch on the transaxle rear cover.
IMPORTANT:
• Air pressure may cause the pistons to jump-out. When removing the piston, hold it with your hand using a waste cloth.
• Take care not to splash automatic transmission fluid (ATF) when air-blowing.
13. Apply 392 kPa (57 psi) of compressed air to the transaxle rear cover to remove the forward clutch piston.

    When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using a needle-nose pliers with vinyl tape on the tip.

Fig 10: Applying Compressed Air To Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Air pressure may cause the drums to jump-out. When removing the drum, hold it with your hand using a waste cloth.
14. Apply 392 kPa (57 psi) of compressed air to the transaxle rear cover to remove the forward clutch drum.

    When the drum can not be removed as it is slanted, either blow the air again with the protruding side pushed or remove the drum using a needle nose pliers with vinyl tape on the tip.

Fig 11: O-Ring & Forward Clutch Drum
Courtesy of GENERAL MOTORS CORP.
15. Using a small screwdriver, remove the O-ring (1) from the forward clutch drum.
Fig 12: O-Ring & Intermediate Shaft Sub-Assembly
Courtesy of GENERAL MOTORS CORP.
16. Using a small screwdriver, remove the O-ring (1) from the intermediate shaft sub-assembly.