1-2-3-4 and 3-5 Reverse Clutch Overhaul
Contents
1. 3 5 Reverse Clutch Waved Plate 3 5 Reverse Clutch Plate Qty 4 3 5 Reverse Clutch Plate Assembly Qty 4 3 5 Reverse Clutch Backing Plate 3 5 Reverse Clutch Backing Plate Retaining Ring Caution Depending on the housing configuration align the retaining ring gap with the missing snap ring groove punch in the housing or the offset punch in the housing Failure to do so may cause damage to the clutch assembly Tip After the retaining ring is installed determine clutch piston travel in order to verify O e O U1 TB ft WI NM o ct http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 10 of 11 i the correct selective retaining ring is being used Refer to 3 5 Reverse Clutch Backing Plate Retaining Ring Measurement 1 2 3 4 and 3 5 Reverse Clutch Bearing Assembly Replacement O 1 2 3 4 and 3 5 Reverse Clutch Bearing Assembly Replacement Callout Component Name 3 5 Reverse Clutch Bearing Caution Install the NEW bearing assembly with the seal side up Improper installation of the bearing may cause damage to the transmission Caution Do not reuse the bearing Install a NEW bearing Reusing an old bearing may cause damage to the transmission Specification Install the bearing flush to 0 3 mm below the thrust surface Special Tools e DT 47865 Bearing Remover e DT 47866 Bearing Installer e 8092 Drive2. Document ID 2187407 Page 1 of 11 2009 Pontiac G8 G8 Service Manual Transmission Automatic Transmission 6L50 6L80 6L90 Repair Instructions Off Vehicle Document ID 2187407 1 2 3 4 and 3 5 Reverse Clutch Overhaul Table 1 1 2 3 4 and 3 5 Reverse Clutch Plates Removal Table 2 1 2 3 4 Clutch Piston Removal Table 3 3 5 Reverse Clutch Piston Removal Table 4 1 2 3 4 and 3 5 Reverse Clutch Piston Seals Replacement Table 5 3 5 Reverse Clutch Piston Installation Table 6 1 2 3 4 Clutch Piston Installation Table 7 1 2 3 4 Clutch Plate Installation Table 8 3 5 and Reverse Clutch Plate Installation Table 9 1 2 3 4 and 3 5 Reverse Clutch Bearing Assembly Replacement 1 2 3 4 and 3 5 Reverse Clutch Plates Removal A gd I p be abe g Prl e afi ag i 1 dm A n 1 2 3 4 and 3 5 Reverse Clutch Plates Removal Callout Component Name 5 Reverse Clutch Backing Plate Retaining Ring 3 3 5 Reverse Clutch Backing Plate 3 5 Reverse Clutch Plate Assembly Qty 4 3 5 Reverse Clutch Plate Qty 4 L http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 2 of 11 5 3 5 Reverse Clutch Waved Plate 6 __ f 5 Reverse Clutch Apply Ring o 2s Clutch Plate Assembly Qy 5 1 2 3 4 Clutch Piston Removal Fi ih UM ay ll pelt a
3. ction Caution Push the retaining ring down over the cone until the ring seats firmly in the retaining ring groove The retaining ring will make a distinctive click sound when it seats Failure to properly seat the retaining ring may cause damage to the 3 5 reverse clutch assembly Tip Use a screwdriver in order to verify the retaining ring is fully seated into the groove It may appear as though the retaining ring is not fully seated since the groove is Shallow by design However this shallow interface is normal Special Tools e DT 47782 1 Retaining Ring Cone e DT 47782 2 Retaining Ring Installer 1 2 3 4 Clutch Piston Inner Seal Caution Install a NEW seal and orientate as shown Failure to do so may cause internal transmission leaks and damage to the transmission 1 2 3 4 Clutch Piston Installation http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 7 of 11 ii ti tS el BS ea oe gt a M E ion z s A pst Ss aan By 7 5 MTA E AT aae T Vise f a Ar ne GA SE ha a a 2 d De A bal Ii E Y 1 2 EBS rs t NA X i ya i ts L Maf SA i ii hi i fe j ifje j yil AAA HOE Mal A q S Lele Le wd y u k I a ra A SA a RSN a4 j gt a i A i T EA N Ve HN EA i J R Hy a fl i Ak i i ji Pex IE oe EN ii aT h IN a aS ret Ha 4 oT Spy see i alll il i ie A al sly TK s
4. e r3 i i F al d inii i ries mar 1 2 3 4 Clutch Piston Removal Callout Component Name 1 2 3 4 Clutch Piston Dam Retaining Ring Caution Use care when compressing the 1 2 3 4 clutch spring and dam assembly Compressing the dam assembly too much may damage it Caution Refer to Retaining Ring Reuse Caution in the Preface section Special Tool J 38734 Intermediate Spring Compressor Adapter http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 3 of 11 2 1 2 3 4 Clutch Piston Dam Assembly 1 2 3 4 Clutch Spring 1 2 3 4 Clutch Piston Tip e It may be necessary to apply air to the apply passage in order to remove the 4 piston Install the 1 2 3 4 clutch housing onto the torque converter with fluid pump housing assembly in order to apply air e After air is applied it may be necessary to turn the housing assembly upside down and carefully tap the housing against a flat surface in order to release the piston 3 5 Reverse Clutch Piston Removal B ii il ML ae arn ciel A By 5 i L a I 4 heal h ln Re P f ar 3 H l lof j j l i i Ae iP N W rome ore Sie Z F a ERK gt k zi 4 Sy A a 1 Re oy AF fi p o y oO i a 3 5 Reverse Clutch Piston Removal Callout Component Name Preliminary Procedure 1 Install the 1 2 3 4 and 3 5 reverse clutch housing ass
5. e external splines is centered over the missing snap ring groove punch in the housing Align the external splines of each remaining steel clutch plate with the first steel clutch plate Failure to do so may cause damage to the clutch assembly 1 2 3 4 Clutch Plate Assembly Qty 5 1 2 3 4 Clutch Backing Plate Caution Align the external splines of the backing plate with the external splines of the steel clutch plates Failure to do so may cause damage to the clutch assembly 1 2 3 4 Clutch Backing Plate Retaining Ring Caution Depending on the housing configuration align the retaining ring gap with the missing snap ring groove punch in the housing or the offset punch in the housing Failure to do so may cause damage to the clutch assembly O v UI pay UJ NO Cc or Tip http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 9 of 11 After the retaining ring is installed determine clutch piston travel in order to verify if the correct selective retaining ring is being used Refer to 1 2 3 4 Clutch Backing Plate Retaining Ring Measurement 3 5 and Reverse Clutch Plate Installation D UJ 5 and Reverse Clutch Plate Installation Component Name 3 5 Reverse Clutch Apply Ring Caution Ensure apply ring legs are positioned into the 3 5 reverse clutch piston Failure to do so may cause damage to the 3 5 reverse clutch assembly
6. eal yet A special tool used to install the 1 2 3 4 clutch piston housing retaining ring may damage the seal if the seal is installed prior to installing the retaining ring Refer to 3 5 Reverse Clutch Piston Installation 1 2 3 4 Clutch Piston Housing Seal 9 1 2 3 4 Clutch Piston Housing Seal y gs ECONA et igre agg Z wii lia Ze gt 2 N 0 i N I Soi b i NE E Pen SSS el i ee a i N t A j d URS i A a a fo i a i ann U R L w NI a Z 3 5 Reverse Clutch Piston Installation Callout Component Name 3 5 Reverse Clutch Piston 3 5 Reverse Clutch Spring Caution Ensure the clutch spring is centered on the piston with the tabs facing up Failure to do so may cause damage to the clutch assembly http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 6 of 11 3 1 2 3 4 Clutch Piston Housing 1 2 3 4 Clutch Piston Housing Retaining Ring Caution Before using the DT 47782 2 push the retaining ring over the DT 47782 1 by hand so that the ring is positioned below the tapered area of the DT 47782 1 If the ring is positioned above the tapered area when it is being installed the ring will become lodged between both tools and damage to the tools retaining ring and piston housing will result Caution Refer to Retaining Ring Reuse Caution in the Preface se
7. embly onto the torque converter with fluid pump housing assembly 2 Apply hand pressure on the 1 2 3 4 clutch piston housing while applying compressed air to the apply passage in order to unseat the 3 5 reverse clutch piston _ Clutch Piston Housing Retaining Ring http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 4 of 11 Caution Refer to Retaining Ring Reuse Caution in the Preface section Special Tool DT 47867 Adjustable Clutch Spring Compressor 1 2 3 4 Clutch Piston Housing 3 5 Reverse Clutch Spring 3 5 Reverse Clutch Piston Tip It may be necessary to turn the housing assembly upside down and carefully tap the housing against a flat surface in order to release the piston 1 2 3 4 and 3 5 Reverse Clutch Piston Seals Replacement 1 2 3 4 and 3 5 Reverse Clutch Piston Seals Replacement Callout Component Name Caution Refer to Seal Reuse Caution in the Preface section Preliminary Procedure Lubricate all seals with automatic transmission fluid ATF prior to installation 1 2 3 4 Clutch Piston Seal SY CT http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 5 of 11 2 3 5 Reverse Clutch Piston Dam O Ring Seal 1 2 3 4 Clutch Piston Inner Seal 7 Caution Do not install a NEW 1 2 3 4 clutch piston inner s
8. ii T BAM H Mol N Q D 4 Ny f i n DAER F Tan SSSA ee e 1 2 3 4 Clutch Piston Installation Component Name 1 1 2 3 4 Clutch Piston 1 2 3 4 Clutch Spring Caution Ensure the clutch spring is centered on the piston with the tabs facing up Failure to do so may cause damage to the clutch assembly 1 2 3 4 Clutch Piston Dam Assembly Tip Lubricate the inner and outer surfaces of the dam assembly with ATF in order to ease installation into the piston Install the tabs facing up Caution Use care when compressing the 1 2 3 4 clutch spring and dam assembly Compressing the dam assembly too much may damage it Caution Refer to Retaining Ring Reuse Caution in the Preface section Special Tool J 38734 Intermediate Spring Compressor Adapter a 1 2 3 4 Clutch Piston Dam Retaining Ring 4 1 2 3 4 Clutch Plate Installation http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 8 of 11 D 4 l N l W l iN Q z cr O gt 0 3 rt D N cr v m O 5 Component Name 1 2 3 4 Clutch Waved Plate Caution To avoid damaging the seal first place J 46624 1 with the small chamfer end facing up and leave in place for at least 60 seconds 1 2 3 4 Clutch Plate Qty 5 Caution Ensure all clutch plates are centered in the housing When installing the first steel clutch plate ensure an opening between th
9. r Handle http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013 Document ID 2187407 Page 11 of 11 e J 45124 Removal Bridge http localhost 9001 si showDoc do docSyskey 2187407 amp pubCellSyskey 145731 amp pubO 5 6 2013
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