GM Service Manual Online
For 1990-2009 cars only

Tools Required

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

    Object Number: 1248104  Size: SH
  1. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install it to the intermediate shaft sub-assembly.

  2. Object Number: 1248108  Size: SH
  3. Coat a new O-ring (1) with ATF, and install it to the forward clutch drum.

  4. Object Number: 1248109  Size: SH

    Important: Do not damage the O-ring and lip seal of forward clutch drum.

  5. Coat the forward clutch drum with ATF, install the forward clutch drum.

  6. Object Number: 1248110  Size: SH

    Important: Do not damage the lip seal of forward clutch return spring.

  7. Coat the forward clutch piston with ATF, install the forward clutch piston.

  8. Object Number: 1246048  Size: SH

    Important: Do not damage the lip seal of forward clutch return spring.

  9. Install the forward clutch return spring and clutch balancer.

  10. Object Number: 1246045  Size: SH
  11. Place the DT 46451  (1) and DT 46452  (2) on the clutch balancer and compress the piston return spring.
  12. Notice: Refer to Transaxle Case Damage Notice in the Preface section.

    Important: Do not expand the snap ring excessively.

  13. Using a snap ring expander, install the snap ring.

  14. Object Number: 1246042  Size: SH
  15. Install the 3 plates (2), 3 discs (3), and the flange (1) in order 2-3-2-3-2-3-1.

  16. Object Number: 1246044  Size: SH
  17. Using a screwdriver, install the snap ring.
  18. Check that the end gap of the snap ring is not aligned with one of the cutouts.

  19. Object Number: 1246043  Size: SH
  20. Install the plate (2), 2 discs (3), and 2 flanges (1) in order 1-3-2-3-1.

  21. Object Number: 1246040  Size: SH
  22. Using a screwdriver, install the snap ring.
  23. Check that the end gap of the snap ring is not aligned with one of the cutouts.
  24. Notice: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in the Preface section.


    Object Number: 1246039  Size: SH
  25. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
  26. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing 392 kPa (57 psi) of compressed air.
  27. • 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).


    Object Number: 1246041  Size: SH
  28. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
  29. 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.
  30. • 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).