GM Service Manual Online
For 1990-2009 cars only

Special Tools

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

    Object Number: 1246028  Size: SH

    Note: Do not expand the ring ends excessively.

  1. Install the seal rings (1) to the input shaft.

  2. Object Number: 1246025  Size: SH
  3. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install the O-ring to the input shaft.

  4. Object Number: 1246021  Size: SH
  5. Coat a new O-ring (1) with ATF and install the O-ring to the direct clutch piston.

  6. Object Number: 1246030  Size: SH

    Note: Do not damage the lip seal of direct clutch piston.

  7. Coat the direct clutch piston with ATF, and install it to the direct clutch drum.

  8. Object Number: 1246022  Size: SH
  9. Install the direct clutch return spring.

  10. Object Number: 1246017  Size: SH
  11. Place DT 46451  (1) and DT 46453  (2) on the return spring and compress.
  12. Note: Do not expand the snap ring excessively.

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

  14. Object Number: 1246031  Size: SH

    Note: Before installing the discs, coat them with ATF.

  15. Install the 2 plates (2), 2 discs (3), and the flange (1) in order: 2-3-2-3-1.

  16. Object Number: 1246019  Size: SH
  17. Using a screwdriver, remove the snap ring.
  18. Check that the end gap of the snap ring is not aligned with one of the cutouts.

  19. Object Number: 1246020  Size: SH
  20. Install the direct clutch on the oil pump.
  21. Caution: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Caution in the Preface section.

  22. Using a dial indicator, measure the direct clutch piston stroke while applying and releasing compressed air.
  23. 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).