CHEVROLET AVEO 2002 Service Repair Manual

DT 46451 (DW240-020) Brake Clutch Spring Compressor. See Special Tools.
DT 46453 (DW240-040) Direct Clutch Adapter. See Special Tools.
Fig. 329: Using A Dial Indicator Measure The Direct Clutch Piston Stroke While Applying
Compressed Air
Courtesy of GENERAL MOTORS CORP.
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 flan
ge.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in
Cautions and Notices.

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Specifications: The piston stroke is 0.4-0.8 mm (0.016-0.031 in).
Fig. 330: Removing Snap Ring Using A Screwdriver

Courtesy of GENERAL MOTORS CORP.
3. Usin
g the screwdriver, remove the snap ring.

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Fig. 331: Flange, Discs & Plates
Courtesy of GENERAL MOTORS CORP.
4. Remove the flange (1), 2 discs (2), and 2 plates (3).

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Fig. 332: 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.
6. Using a snap ring expander, remove the snap ring.
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.

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Fig. 333: Direct Clutch Return Spring
Courtesy of GENERAL MOTORS CORP.
7. Remove the direct clutch return sprin
g.

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Fig. 334: Direct Clutch & Oil Pump
Courtesy of GENERAL MOTORS CORP.
8. Install the direct clutch on the oil pump.
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 usin
g needle nose pliers with vinyl tape on the tip.
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.

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Fig. 335: O-Ring & Direct Clutch Piston
Courtesy of GENERAL MOTORS CORP.
10. Usin
g a small screwdriver, remove the O-ring (1) from the direct clutch piston.

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Fig. 336: O-Ring & Input Shaft
Courtesy of GENERAL MOTORS CORP.
11. Remove the O-ring (1) from the input shaft.

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Fig. 337: Seal Rings & Input Shaft
Courtesy of GENERAL MOTORS CORP.
12. Remove the 2 seal rings (1) from the input shaft.
DIRECT CLUTCH INSPECTION
IMPORTANT: Do not expand the ring ends excessively.

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Fig. 338: Checking The Sliding Surface Of Disc, Plate & Flange For Damage
Courtesy of GENERAL MOTORS CORP.
1. Check to see if the sliding surface of the disc, plate, and flange are worn or burnt. If necessary, replace
them.
If the lining of the disc is peeling off or discolored, or even if a part of the printed number is
defaced, replace all discs.
CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

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