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: Seal Rings & Input Shaft
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: O-Ring & Input Shaft
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: O-Ring & Direct Clutch Piston
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: Direct Clutch Drum & 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: Direct Clutch Return Spring
Courtesy of GENERAL MOTORS CORP.
5. Install the direct clutch return spring.
Fig 6: Return Spring, Compress, DT 46451 & DT 46453
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: Plates, Discs & 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: Using A Dial Indicator Measure The Direct Clutch Piston Stroke While Applying Compressed Air
Courtesy of GENERAL MOTORS CORP.
11. Install the direct clutch on the oil pump.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice .
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).