FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Geo >> 1996 >> Metro L3-061 1.0L VIN 6 TBI >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul >> Component Repair and Transaxle Reassembly >> Input Clutch Assemblies >> Forward Clutch

Forward Clutch






Measure

^ Tool Required:
- J 26900-5 Vernier Caliper





- Forward clutch clearance by using a J 26900-5 and measuring the height between the forward clutch plate snap ring and the forward clutch flange. If the height between the forward clutch plate snap ring and the forward clutch flange measures 2.01 to 2.68 mm (0.079 to 0.105 inch), the forward clutch clearance is within specification. If the measurement is larger than specification, replace the forward clutch discs and/or plates.

REMOVE OR DISCONNECT

^ Tools Required:
- J 23327 Clutch Spring Compressor
- J 25018-A Clutch Spring Compressor Adapter

1. Input shaft seal rings.
2. Direct clutch washer.
3. Input shaft bearing and bearing races.
4. Forward clutch plate snap ring.





5. Forward clutch flange, discs and plates.





- Install a J 23327 with a J 25018-A and place in a hydraulic press. Compress the forward clutch spring seat until the forward clutch spring seat snap ring can be removed. DO NOT compress the return springs more than necessary.

CAUTION: Use a screwdriver to remove the forward clutch return spring snap ring. Keep fingers and hands away from the hydraulic press arbor and the forward clutch return spring seat. Once the forward clutch spring seat snap ring is removed, release the hydraulic press slowly. If this precaution is not observed, serious injury may result.

6. Forward clutch spring seat snap ring.
7. Forward clutch spring seat and return springs.





8. Forward clutch piston. Slowly apply low pressure compressed air into the input shaft fluid inlet hole. If the piston does not pop out, carefully lift the piston out with needle nose pliers.
9. Forward clutch piston inner and outer seals.

Inspect
- Forward clutch piston check valve (steel ball) for free movement and for leakage by using low pressure compressed air. If leaks exist, replace piston.
- Forward clutch drum for burrs, scars or other damage.
- Input shaft and seal ring grooves for burrs or sharp edges.

INSTALL OR CONNECT

^ Tools Required:
- J 36850 Transjel Transmission Assembly Lubricant
- J 23327 Clutch Spring Compressor
- J 25018-A Clutch Spring Compressor Adapter

1. New inner and outer seals to forward clutch piston. Lubricate with J 36850.
2. Forward clutch piston into forward clutch drum.

Important
- Use caution not to twist, cut or tear seals.





3. Eighteen forward clutch piston return springs and spring seat.
4. The J 23327 with the J 25018-A and place in a hydraulic press. Compress the forward clutch spring seat until the spring seat snap ring can be installed. DO NOT compress the return springs more than what is necessary to install forward clutch spring seat snap ring.
5. Forward clutch spring seat snap ring.

NOTICE: Make sure that the forward clutch snap ring is securely seated in the four projections of the forward clutch spring seat. DO NOT compress the forward clutch return spring assembly more than what is necessary to fit the forward clutch spring seat snap ring.

NOTICE: When installing new clutch discs in the 1 st-reverse brake, forward clutch or direct clutch assemblies, the new clutch discs MUST be soaked in Dexron(R) III automatic transmission fluid GM P/N 12341643, or equivalent, two hours prior to installation. This causes the clutch material on the discs to permeate with fluid which will aid in ease of assembly and prevent clutch overheating on first time engagement.

6. Forward clutch discs and plates alternately in the following order:
A. Plate
B. Disc
C. Plate
D. Disc
E. Plate
F. Disc
7. Forward clutch flange.
8. Forward clutch plate snap ring.

Measure

^ Tool Required:
- J 26900-S Vernier Caliper





- Forward clutch clearance by using a J 26900-S and measuring the height between the forward clutch plate snap ring and the forward clutch flange. If the height between the forward clutch plate snap ring and the forward clutch flange measures 2.01 to 2.68 mm (0.079 to 0.105 inch), the forward clutch clearance is within specification. If the measurement is larger than specification, replace the forward clutch discs and/or plates.
- If the measurement falls out of specification with new forward clutch discs and plates installed, install a flange of a different thickness. There are two sizes of clutch flanges available:
Thickness 3.00 mm (0.118-inch)
Thickness 3.37 mm (0.132-inch)

Inspect
- Forward clutch piston for operation by slowly applying low pressure compressed air through the drum fluid inlet hole. The piston should return to its original position after air pressure is released.





9. Input shaft seal rings. Lubricate with J 36850.
10. Align the inner teeth of the direct clutch discs.





11. Inner direct clutch washer to the direct clutch drum with the grooved side facing outward. Lubricate with J 36850.





12. Direct clutch assembly onto the input shaft and onto the forward clutch drum making sure the grooves between the teeth of the direct clutch discs align with the splines of the forward clutch drum. Twist the direct clutch assembly while working downward onto the forward clutch drum.

Inspect
- Direct clutch drum for proper installation by moving it up and down gently by hand. If assembled correctly, a "click" sound will be heard from the direct clutch drum. If no "click" sound is heard, the direct clutch drum may be incorrectly installed. If so, remove the direct clutch drum from the forward clutch drum and input shaft and reposition as necessary.

13. Lubricate front planetary ring gear outer bearing and races with J 36850.





14. Front planetary ring gear outer bearing and races in the following order:
A. No. 2 race-outside diameter 35.8 mm (1.40-inch), flange side down.
B. Bearing
C. No. 1 race-outside diameter 37.9 mm (1.49-inch), flange side down.





15. Align the inner teeth of the forward clutch discs. Lubricate the output shaft seal ring with J 36850.





16. Input shaft and forward/direct clutch assembly. Lower the assembly onto the front planetary ring gear making sure the grooves between the teeth of the forward clutch discs align with the splines of the front planetary ring gear. Twist the assembly while working downward onto the ring gear.

Inspect
- Input shaft and forward /direct clutch assembly for proper installation by moving it up and down gently by hand. If assembled correctly, a "click" sound will be heard from the forward clutch drum. If no "click" sound is heard, the input shaft and forward/direct clutch assembly may be incorrectly installed. If so, remove the input shaft and forward/direct clutch assembly from the front planetary ring gear and reposition as necessary.

Measure

^ Tool Required:
- J 26900-S Vernier Caliper





Input shaft flange depth by placing a straightedge across the front of the transaxle case and measuring the distance between the top of the input shaft flange and the bottom of the straightedge with a J 26900-5. The measurement must fall within 49.82 to 51.06 mm (1.962 to 2.010-inch). If the measurement is within specification, all components, with the exception of the direct clutch assembly, are installed correctly. If the measurement does not fall within the specification, remove components and install or reposition correctly and remeasure to verify correct installation.

17. Lubricate intermediate band anchor pin with J 36850.





18. Intermediate band anchor pin by aligning the strap in the intermediate band with the case anchor pin hole and insert anchor pin.





19. Make sure the piston rod is engaged into the intermediate band.





20. New intermediate band cover gasket.
21. Intermediate band cover and four bolts.

Tighten
- Intermediate band cover bolts to 9 N.m (80 lb. in.).

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