CHEVROLET AVEO 2002 Service Repair Manual

Fig. 379: Clutch Balancer & Forward Clutch Return Spring
Courtesy of GENERAL MOTORS CORP.
5. Install the forward clutch return spring and clutch balancer.
IMPORTANT: Do not damage the lip seal of forward clutch return spring.

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Fig. 380: Compressing Spring Using DT 46451 & DT 46452
Courtesy of GENERAL MOTORS CORP.
6. Place the DT 46451 (1) and DT 46452 (2) on the clutch balancer and compress the piston return spring.
See Special Tools
.
7. Using a snap ring expander, install the snap ring.
IMPORTANT: Do not expand the snap ring excessively.

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Fig. 381: Flanges, Discs, Plate & Forward Clutch Drum
Courtesy of GENERAL MOTORS CORP.
8. Install the 3 plates (2), 3 discs (3), and the flange (1) in order 2-3-2-3-2-3-1.

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Fig. 382: Removing Forward/Reverse Clutch Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
9. Using a screwdriver, install the snap ring.
10. Check that the end gap of the snap ring is not aligned with one of the cutouts.

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Fig. 383: Flanges, Discs, Plate & Reverse Clutch Drum
Courtesy of GENERAL MOTORS CORP.
11. Install the plate (2), 2 discs (3), and 2 flan
ges (1) in order 1-3-2-3-1.

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Fig. 384: Removing Reverse Clutch Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
12. Using a screwdriver, install the snap ring.
13. Check that the end
gap of the snap ring is not aligned with one of the cutouts.

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Fig. 385: Measuring Reverse Clutch Pack Clearance While Applying Compressed Air
Courtesy of GENERAL MOTORS CORP.
14. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
15. Usin
g a dial indicator, measure the reverse clutch pack clearance while applying and releasing 392 kPa
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice .

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(57 psi) of compressed air.
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).

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Fig. 386: Measuring Forward Clutch Pack Clearance While Applying Compressed Air
Courtesy of GENERAL MOTORS CORP.
16. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
17. 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. See Special Tools
.
The forward and reverse clutch will come out as you apply the compressed air. Therefore, while the
checkin
g is being done, press on the input shaft of the forward and reverse clutch using stamping

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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).
COUNTER DRIVE GEAR DISASSEMBLE
Fig. 387: Removing Tapered Roller Bearing From Transaxle Case Side Using A Puller

Courtesy of GENERAL MOTORS CORP.

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