CHEVROLET AVEO 2002 Service Repair Manual

Fig. 369: Forward/Reverse Multiple Disc Clutch & Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
12. Install the forward and reverse multiple disc clutch on the transaxle rear cover.
13. Apply 392 kPa (57 psi) of compressed air to the transaxle rear cover to remove the forward clutch piston.
When the piston cannot be removed as it is slanted, either blow the air again with the protruding side
pushed or remove the piston usin
g a needle-nose pliers with vinyl tape on the tip.
IMPORTANT:Air pressure may cause the pistons to jump-out. When removing the
piston, hold it with your hand using a waste cloth.
Take care not to splash automatic transmission fluid (ATF) when air-
blowing.

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Fig. 370: Applying Compressed Air To Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
14. Apply 392 kPa (57 psi) of compressed air to the transaxle rear cover to remove the forward clutch drum.
When the drum can not be removed as it is slanted, either blow the air again with the protruding side
pushed or remove the drum using a needle nose pliers with vinyl tape on the tip.
IMPORTANT: Air pressure may cause the drums to jump-out. When removing the drum,
hold it with your hand using a waste cloth.

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Fig. 371: O-Ring & Forward Clutch Drum
Courtesy of GENERAL MOTORS CORP.
15. Usin
g a small screwdriver, remove the O-ring (1) from the forward clutch drum.

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Fig. 372: O-Ring & Intermediate Shaft Sub-Assembly
Courtesy of GENERAL MOTORS CORP.
16. Using a small screwdriver, remove the O-ring (1) from the intermediate shaft sub-assembly.
FORWARD AND REVERSE CLUTCH INSPECTION

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Fig. 373: Checking Forward/Reverse Clutch 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.
Before assembling new discs, soak them in ATF for at least 15 minutes.

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Fig. 374: Measuring Free Length Of Spring Using Vernier Calipers
Courtesy of GENERAL MOTORS CORP.
2. Using vernier calipers, measure the free length of the spring together with the spring seat.
Specifications: The standard free length is 24.04 mm (0.9465 in).
FORWARD AND REVERSE CLUTCH ASSEMBLE
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. 375: O-Ring & Intermediate Shaft Sub-Assembly
Courtesy of GENERAL MOTORS CORP.
1. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install it to the intermediate shaft sub-
assembly.

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Fig. 376: O-Ring & Forward Clutch Drum
Courtesy of GENERAL MOTORS CORP.
2. Coat a new O-rin
g (1) with ATF, and install it to the forward clutch drum.

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Fig. 377: Forward Clutch Drum, O-Ring, Lip Seal & ATF
Courtesy of GENERAL MOTORS CORP.
3. Coat the forward clutch drum with ATF, install the forward clutch drum.
IMPORTANT: Do not damage the O-ring and lip seal of forward clutch drum.

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Fig. 378: Forward Clutch Drum, Lip Seal & ATF
Courtesy of GENERAL MOTORS CORP.
4. Coat the forward clutch piston with ATF, install the forward clutch piston.
IMPORTANT: Do not damage the lip seal of forward clutch return spring.

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