Direct Clutch Assembly Disassemble

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: Using A Dial Indicator Measure The Direct Clutch Piston Stroke While Applying Compressed Air
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in Cautions and Notices.
1. Install the direct clutch and thrust needle roller bearing on the oil pump.
2. Using a dial indicator, measure the direct clutch piston stroke while applying and releasing 392 kPa (57 psi) of compressed air.

   If the stroke is non-standard, inspect the discs, the plates, and the flange.

   Specifications:  The piston stroke is 0.4-0.8 mm (0.016-0.031 in).

Fig 2: Removing Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
3. Using the screwdriver, remove the snap ring.
Fig 3: Flange, Discs & Plates
Courtesy of GENERAL MOTORS CORP.
4. Remove the flange (1), 2 discs (2), and 2 plates (3).
Fig 4: Return Spring, Compress, DT 46451 & DT 46453
Courtesy of GENERAL MOTORS CORP.
5. Place the DT 46451  (1) and DT 46453  (2) on the direct clutch return spring and compress. See Special Tools .
NOTE: Do not depress the direct clutch piston return spring lower than 1-2 mm (0.039-0.078 in.) beyond the snap ring groove. This will prevent the direct clutch piston return spring from becoming distorted.
IMPORTANT: Do not expand the snap ring excessively.
6. Using a snap ring expander, remove the snap ring.
Fig 5: Direct Clutch Return Spring
Courtesy of GENERAL MOTORS CORP.
7. Remove the direct clutch return spring.
Fig 6: Direct Clutch & Oil Pump
Courtesy of GENERAL MOTORS CORP.
8. Install the direct clutch on the oil pump.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in Cautions and Notices.
IMPORTANT: Air pressure may cause the pistons to jump-out. When removing the piston, hold it with your hand using a waste cloth.
IMPORTANT: Do not splash ATF when air-blowing.
9. Apply 392 kPa (57 psi) of compressed air to the oil pump to remove the direct clutch piston.

   When the piston can not be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using needle nose pliers with vinyl tape on the tip.

Fig 7: O-Ring & Direct Clutch Piston
Courtesy of GENERAL MOTORS CORP.
10. Using a small screwdriver, remove the O-ring (1) from the direct clutch piston.
Fig 8: O-Ring & Input Shaft
Courtesy of GENERAL MOTORS CORP.
11. Remove the O-ring (1) from the input shaft.
Fig 9: Seal Rings & Input Shaft
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Do not expand the ring ends excessively.
12. Remove the 2 seal rings (1) from the input shaft.