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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1459 (Automatic Transaxle - AF33-5 (Removal & Installation, Service & Overhaul)) >> Repair Instructions >> Forward and Direct Clutch Assembly Assemble

Forward and Direct Clutch Assembly Assemble

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

Tools Required

    Fig 1: Applying Compressed Air To Check For Leaks
    GM749686Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Soak the new clutch discs in automatic transmission fluid for at least 2 hours before installation.
  1. Inspect the sliding surface of the disc and the plate for being worn or burnt. Replace the disc if it is worn or burnt.
  2. Shake the piston to be sure the ball check valve is free.
    3. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.
  3. Apply compressed air to the ball check valve to be sure it is not leaking.
    4. Fig 2: View Of Forward Clutch Piston & Seals
    GM749685Courtesy of GENERAL MOTORS CORP.
  4. Apply automatic transmission fluid to the new forward clutch piston seals.
  5. Install the forward clutch piston inner seal (564) and the forward clutch piston outer seal (566) onto the forward clutch piston (565).
  6. Apply automatic transmission fluid to the inner surface of the forward clutch drum.
    7. IMPORTANT: Do not damage the forward clutch piston seals.
  7. Press the forward clutch piston (565) into the forward and direct clutch housing assembly - with input shaft.
    8. Fig 3: View Of Direct Clutch Piston & Seals
    GM749682Courtesy of GENERAL MOTORS CORP.
  8. Apply automatic transmission fluid to the new direct clutch piston seals.
  9. Install the direct clutch piston inner seal (561) and the direct clutch piston outer seal (563) onto the direct clutch piston (562).
  10. Apply automatic transmission fluid to the inner surface of the forward clutch piston.
    11. IMPORTANT: Do not damage the direct clutch piston seals.
  11. Press the direct clutch piston (562) into the forward clutch piston.
    12. Fig 4: View Of Direct Clutch Spring Assembly
    GM749676Courtesy of GENERAL MOTORS CORP.
  12. Install the direct clutch spring assembly (560) onto the direct clutch piston, indexing the springs into the holes in the direct clutch piston (562).
    13. Fig 5: Removing/Installing Direct Clutch Spring Retaining Ring
    GM749670Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not align the end gap of the direct clutch spring retaining ring (559) with the spring retainer claw.
  13. Install J 45186  (2) onto the shaft of the forward and direct clutch housing assembly - with input shaft (567). See Special Tools . Place J 21420-2 (4), which is part of J 23327  , on the bottom of the forward and direct clutch housing assembly - with input shaft (567). See Special Tools . Position J 25024-A  (1) as shown and compress the direct clutch spring assembly. See Special Tools .
  14. Place the assembly in a vise, holding by J 25024-A  (1). See Special Tools .
  15. Install the direct clutch spring retaining ring (559) in the groove of the input shaft assembly with J 28585  (3). See Special Tools .
  16. Remove the tools.
    17. Fig 6: View Of Forward & Direct Clutch Housing Assembly Clutch Plates
    GM749665Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure the direct clutch apply plate is facing the correct direction.
  17. Install the direct clutch apply plate (558).
    18. IMPORTANT: Make sure you have the correct number of plates, and that they are installed in the proper direction.
  18. Install the 4 direct clutch steel plates (557) and the 4 direct clutch fiber plates (556).
  19. Install the direct clutch backing plate (555).
    20. Fig 7: View Of Direct Clutch Backing Plate Retaining Ring
    GM749661Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure that the end gap of the direct clutch backing plate retaining ring (554) is not aligned with any of the cut-outs.
  20. Install the direct clutch backing plate retaining ring (554) into the groove in the forward and direct clutch housing assembly - with input shaft (567) using J 28585  . See Special Tools .
    21. Fig 8: Exploded View Of Forward & Direct Clutch Housing Assembly
    GM749647Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure you have the correct number of plates, and that they are installed in the proper order.
  21. Install the 4 forward clutch steel plates (553) and the 4 forward clutch fiber plates (552).
  22. Install the forward clutch backing plate (551).
    23. Fig 9: Removing Forward Clutch Backing Plate Retaining Ring
    GM749645Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure that the end gap of the forward clutch backing plate retaining ring (550) is not aligned with any of the cut-outs.
  23. Install the forward clutch backing plate retaining ring (550) into the groove in the forward and direct clutch housing assembly - with input shaft (567) using J 28585  . See Special Tools .
    24. Fig 10: View Of Forward Clutch Housing Thrust Bearing & Selective Race
    GM749641Courtesy of GENERAL MOTORS CORP.
  24. Install the forward clutch housing selective thrust bearing race (568) and the forward clutch housing thrust bearing (569).
    25. Fig 11: View Of Input Shaft & O-Ring Seal
    GM749640Courtesy of GENERAL MOTORS CORP.
  25. Apply automatic transmission fluid to the new input shaft O-ring seal (570).
  26. Install the new input shaft O-ring seal (570) into the groove of the forward and direct clutch housing assembly - with input shaft (567).
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