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Home >> Pontiac >> 2009 >> Solstice Base, 2D Convertible, Automatic >> Repair and Diagnosis >> Transmission >> Hydraulic Diagrams >> Automatic Transmission - 5L40-E - Removal & Installation, Service, Overhaul, Troubleshooting & Diagnosis >> Repair Instructions - Off Vehicle >> Forward and Coast Clutch Assemble

Forward and Coast Clutch Assemble

Special Tools

For equivalent regional tools, refer to Special Tools .

    Fig 1: View Of Forward Clutch Housing
    GM802347Courtesy of GENERAL MOTORS CORP.
  1. Inspect the forward clutch housing (433) for the following:
    • Plugged feed passages
    • Damaged ball check valve (434)
    • Worn or damaged splines
    • Seal ring groove nicks or burrs
    • Cracked or blocked fluid passages in the input shaft
    • Worn or damaged clutch plates
  2. Inspect the input shaft fluid seals (431, 432) for worn or damaged seals.
  3. Slide J 45130-3:  seal protector (2) over the input shaft, and position J 45130-3:  seal protector (2) at the seal groove closest to the housing. Coat J 45130-3:  seal protector (2) with transmission fluid.
  4. Guide a NEW seal (431) onto J 45130-3:  seal protector (2) and slide the seal into the groove with J 45130-2:  seal installer pusher (1).
    5. Fig 2: Locating Input Shaft Fluid Seals
    GM816727Courtesy of GENERAL MOTORS CORP.
  5. Remove J 45130-3:  seal protector.
  6. Install the input shaft fluid seals (432).
    7. Fig 3: Sizing Seals
    GM801887Courtesy of GENERAL MOTORS CORP.
  7. Size the seals (431, 432) with J 45130-1:  seal installer sizer.
  8. Leave J 45130-1:  seal installer sizer in place for at least five minutes. If possible, leave J 45130-1:  seal installer sizer in place until you install the assembly into the transmission case.
    9. Fig 4: Inspecting Forward Clutch Piston
    GM801888Courtesy of GENERAL MOTORS CORP.
  9. Inspect the forward piston and the coast clutch piston for the following:
    • Cracks or damage to seal grooves
    • Wear on the piston
    • Worn or damaged clutch plates
  10. Use J 45134:  seal protector to install the forward clutch piston (436).
    11. Fig 5: Locating Coast Clutch Piston
    GM801889Courtesy of GENERAL MOTORS CORP.
  11. Use J 45132:  seal protector to install the coast clutch piston (438).
    12. Fig 6: Compressing Forward & Coast Clutch Spring
    GM801882Courtesy of GENERAL MOTORS CORP.
  12. Inspect the forward and coast clutch piston spring for the following:
    • Damaged cage
    • Distorted or missing springs
  13. Install the piston spring (439).
  14. Use J 43074:  spring compressor to compress the spring and install the retainer ring (440).
    15. Fig 7: Measuring Dimension A
    GM851060Courtesy of GENERAL MOTORS CORP.
  15. Measure the distance from the top of the forward clutch housing to the coast clutch piston (438), record this as dimension C.
  16. Measure the distance from the top of the forward clutch housing to the forward clutch piston (436), record this as dimension B.
  17. Subtract dimension C from dimension B. This is now dimension A.
    18. Fig 8: Measuring Coast Clutch Pack Travel
    GM851062Courtesy of GENERAL MOTORS CORP.
  18. Install the coast clutch backing plate (445) into the coast clutch housing (446).
  19. Install the coast clutch plates into the coast clutch housing (446). Starting with the coast clutch plate (444) with inner splines. Alternating with the coast clutch plate (443) with outer splines. Refer to Clutch Plate Selection Specifications .
  20. Install the coast clutch apply plate into the coast clutch housing (446).
  21. Install the coast clutch spacer plate (441) into the coast clutch housing (446).
  22. Measure the distance from the top of the coast clutch housing (446) to the top of the coast clutch spacer plate (441), record this as dimension B.
  23. Subtract dimension B from dimension A, this is clutch pack travel.
    24. Fig 9: Identifying Coast Clutch Components
    GM801881Courtesy of GENERAL MOTORS CORP.
  24. Install the coast clutch spacer plate (441).
  25. Install the coast clutch apply plate (442).
  26. Install the coast clutch plates. Starting with the coast clutch plate (443) with the outer splines. Refer to Clutch Plate Selection Specifications .
  27. Alternating with the coast clutch plate (444) with inner splines.
  28. Install the coast clutch backing plate (444).
  29. Install the coast clutch housing (446).
    30. Fig 10: Identifying Forward Clutch Plates
    GM801880Courtesy of GENERAL MOTORS CORP.
  30. Install the forward clutch apply plate (447).
  31. Install the forward clutch plates. Starting with the forward clutch plate (448) with outer splines. Alternating with the forward clutch plate (449) with inner splines. Refer to Clutch Plate Selection Specifications .
  32. Install the forward clutch backing plate (450).
  33. Install the forward clutch backing plate retainer ring (451).
    34. Fig 11: Measuring Clutch Pack Travel
    GM816729Courtesy of GENERAL MOTORS CORP.
  34. Measure the distance between the forward clutch backing plate and the bottom of the gage bar. Measure three times in different locations on the backing plate. Record this as H1.
  35. Apply air pressure to the specified port. Measure the distance between the forward clutch backing plate and the bottom of the gage bar. Measure three times in different locations on the backing plate. Record this as H2.
  36. Subtract H2 from H1 this is the clutch pack travel. Refer to Clutch Piston Travel Specifications .
  37. At this time you do not install the forward and coast clutch assembly into the transmission case. Set aside until told to do so.
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