CHEVROLET AVEO 2002 Service Repair Manual

Before assembling new discs, soak them in ATF for at least 15 minutes.
Fig. 339: Measuring The Free Length Of Direct Clutch Return Spring Using Vernier Calipers

Courtesy of GENERAL MOTORS CORP.
2. Using vernier calipers, measure the free length of the direct clutch return spring together with the spring
sheet.
Specifications: Standard free len
gth is 36.04 mm (1.4189 in).

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Fig. 340: Applying Low-Pressure Compressed Air To Direct Clutch Piston
Courtesy of GENERAL MOTORS CORP.
3. Check that the check ball is free by shaking the direct clutch piston.
4. Check that the valve does not leak by applying low-pressure compressed air.
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.

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Fig. 341: Seal Rings & Input Shaft
Courtesy of GENERAL MOTORS CORP.
1. Install the 2 seal rin
gs (1) to the input shaft.
IMPORTANT: Do not expand the ring ends excessively.

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Fig. 342: O-Ring & Input Shaft
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2. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install the O-ring to the input shaft.

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Fig. 343: 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. 344: Direct Clutch Drum & Direct Clutch Piston

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Courtesy of GENERAL MOTORS CORP.
4. Coat the direct clutch piston with ATF, and install it to the direct clutch drum.
Fig. 345: Direct Clutch Return Spring

Courtesy of GENERAL MOTORS CORP.
5. Install the direct clutch return sprin
g. IMPORTANT: Do not damage the lip seal of direct clutch piston.

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Fig. 346: 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
.
7. Usin
g a snap ring expander, install the snap ring.
IMPORTANT: Do not expand the snap ring excessively.

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Fig. 347: Plates, Discs & Flange
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8. Install the 2 plates (2), 2 discs (3), and the flan
ge (1) in order: 2-3-2-3-1.
IMPORTANT: Before installing the discs, coat them with ATF.

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Fig. 348: 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.

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Fig. 349: 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.
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.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice .

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