Direct Clutch Assembly Assemble

Tools Required

• DT 46451  (DW240-020) Brake/Clutch Spring Compressor. See Special Tools .
• DT 46453  (DW240-040) Direct Clutch Adapter. See Special Tools .

Fig 1: View Of Input Shaft And Seal Rings
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Do not expand the ring ends excessively.
1. Install the 2 seal rings (1) to the input shaft.
Fig 2: View Of Input Shaft And O-Ring
Courtesy of GENERAL MOTORS CORP.
2. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install the O-ring to the input shaft.
Fig 3: View Of Direct Clutch Piston And O-Ring
Courtesy of GENERAL MOTORS CORP.
3. Coat a new O-ring (1) with ATF and install the O-ring to the direct clutch piston.
Fig 4: View Of Direct Clutch Drum And Direct Clutch Piston
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Do not damage the lip seal of direct clutch piston.
4. Coat the direct clutch piston with ATF, and install it to the direct clutch drum.
Fig 5: View Of Direct Clutch Return Spring
Courtesy of GENERAL MOTORS CORP.
5. Install the direct clutch return spring.
Fig 6: View Of DT 46451 And DT 46453 Spring Compression Tools
Courtesy of GENERAL MOTORS CORP.
6. Place the DT 46451  (1) and the DT 46453  (2) on the return spring and compress. See Special Tools .
IMPORTANT: Do not expand the snap ring excessively.
7. Using a snap ring expander, install the snap ring.
Fig 7: View Of Plates, Discs And Flange
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Before installing the discs, coat them with ATF.
8. Install the 2 plates (2), 2 discs (3), and the flange (1) in order: 2-3-2-3-1.
Fig 8: Removing Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
9. Using a screwdriver, remove the snap ring.
10. Check that the end gap of the snap ring is not aligned with one of the cutouts.
Fig 9: Measuring Direct Clutch Piston Stroke While Applying Compressed Air
Courtesy of GENERAL MOTORS CORP.
11. Install the direct clutch on the oil pump.
12. Using a dial indicator, measure the direct clutch piston stroke while applying and releasing 392 kPa (57 psi)  of compressed air.

    Specifications:  The piston stroke is 0.4-0.8 mm (0.016-0.031 in).

    • If the piston stroke is less than the limit of piston stroke, parts may have been assembled incorrectly, so check and reassemble again.
    • If the stroke is non-standard, select another flange.
    • There are 3 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).