CHEVROLET AVEO 2002 Service Repair Manual

Fig. 360: Turning Rear Planetary Sun Gear & One-Way Clutch
Courtesy of GENERAL MOTORS CORP.
4. Install the one-way clutch and thrust washer to the rear planetary sun gear.
5. Hold the rear planetary sun gear and turn the one-way clutch. The one-way clutch should turn freely
clockwise and should lock counterclockwise.
FORWARD AND REVERSE CLUTCH DISASSEMBLE
Tools Required
DT 46451 (DW240-020) Brake/Clutch Spring Compressor. See Special Tools.
DT 46452 (DW240-030) Forward Clutch Adapter. See Special Tools.
DT 46520 (DW240-120) Measuring Terminal. See Special Tools.

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Fig. 361: Measuring Reverse Clutch Pack Clearance While Applying Compressed Air
Courtesy of GENERAL MOTORS CORP.
1. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
2. 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 stroke is non-standard, inspect the discs, plates, and flange.
Specifications: The pack clearance is 0.4-1 mm (0.0157-0.0394 in).
Fig. 362: Measuring Forward Clutch Pack Clearance While Applying Compressed Air

Courtesy of GENERAL MOTORS CORP.

2006 Chevrolet Aveo
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3. Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover.
4. Using a dial indicator and the DT 46520 (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
checking is being done, press on the input shaft of the forward and reverse clutch using stamping
machine or alike so that the pressure is not applied on the forward and reverse clutch.
If the stroke is non-standard, inspect the discs, plates and flange.
Specifications: The pack clearance is 1.1-1.5 mm (0.043-0.059 in).

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Fig. 363: Removing Reverse Clutch Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
5. Usin
g a screwdriver, remove the reverse clutch snap ring.

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Fig. 364: Flanges, Discs, Plate & Reverse Clutch Drum
Courtesy of GENERAL MOTORS CORP.
6. Remove the 2 flan
ges (1), the 2 discs (3), and the plate (2) from the reverse clutch drum.

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Fig. 365: Removing Forward/Reverse Clutch Snap Ring Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
7. Using a screwdriver, remove the snap ring.

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Fig. 366: Flanges, Discs, Plate & Forward Clutch Drum
Courtesy of GENERAL MOTORS CORP.
8. Remove the flange (1), 3 discs (3), and 3 plates (2) from the forward clutch drum.

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Fig. 367: Compressing Spring Using DT 46451 & DT 46452
Courtesy of GENERAL MOTORS CORP.
9. Using the DT 46451 (1) and the DT 46452 (2), compress the spring. See Special Tools
.
10. Usin
g a snap ring expander, remove the snap ring.
IMPORTANT: Do not expand the snap ring excessively.

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Fig. 368: Clutch Balancer & Forward Clutch Return Spring
Courtesy of GENERAL MOTORS CORP.
11. Remove the clutch balancer and forward clutch return sprin
g.

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