Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: 3-5-Reverse and 4-5-6 Clutch Housing Assemble (6T30/40/45/50 - Gen 2)

Chevrolet Sonic Repair Manual / Powertrain / Transmission/Transaxle / Automatic / General / 3-5-Reverse and 4-5-6 Clutch Housing Assemble (6T30/40/45/50 - Gen 2)

Table 1: 4?? Clutch Piston Installation
Table 2: 4?? Clutch Fluid Dam Installation
Table 3: 3? Reverse Clutch Plates Installation
Table 4: Reluctor Wheel and Piston Installation
Table 5: 4?? Clutch Plates Installation
Table 6: Turbine Shaft Installation
4?? Clutch Piston Installation


4?? Clutch Piston Installation

Callout

Component Name

1

4?? Clutch Piston Inner Seal

2

4?? Clutch Piston Outer Seal (Large) (Rounded)

3

4?? Clutch Piston Outer Seal (Dark Blue) (Stepped)

4

4?? Clutch Piston

Note:

  • DT-47805 seal protector prevents the piston seal lip from damage during installation. Apply a thin coat of ATF to the I.D. of DT-47805 seal protector to ease the installation of the piston.
  • DT-47951-2 spring compressor can be used as a pusher if necessary.
Special Tools

  • DT-47805 Seal Protector
  • DT-47951-2 Spring Compressor

For equivalent regional tools, refer to Special Tools.

4?? Clutch Fluid Dam Installation


4?? Clutch Fluid Dam Installation

Callout

Component Name

1

4?? Clutch Piston Return Spring Assembly

2

4?? Clutch Piston Fluid Dam Assembly

Note:

The seal protector prevents the dam seal lip from damage during installation. Apply a thin coat of ATF to the I.D. of the seal protector to ease the installation of the dam.

Special Tools

  • DT-47951-1 Seal Protector for 6T40/45 applications
  • DT-50117 Seal Protector for 6T50 applications

For equivalent regional tools, refer to Special Tools.

3

4?? Clutch Dam Retaining Ring

Caution:

Regulate the air pressure to 276 kPa (40 psi) maximum. High pressure could cause the piston to over travel and damage the piston seals.

Procedure

  1. Leave the seal protector on the clutch housing while installing the retaining ring. Install the dam retainer clips DT 50117-1 seal protector to hold the seal protector in place.
  2. Use DT 46620-2 retaining clips and DT 50573 ring guide to install a NEW 4-5-6 clutch dam retaining ring. Assemble the ring ??leg facing down, DT 50573 and DT 46620 and insert as an assembly onto the clutch hub to install the ring.
  3. Place the housing assembly onto the input shaft support inside the case. Apply shop air to the clutch fluid feed hole in the case to verify proper piston operation.
Special Tools

  • DT-47951-2 Spring Compressor
  • DT 46620 Seal Installer
  • DT 50117-1 Seal Protector
  • DT 50117-2 Seal Protector Retaining Clips
  • DT 50573 Retaining Ring Installer

For equivalent regional tools, refer to Special Tools.

3? Reverse Clutch Plates Installation


3? Reverse Clutch Plates Installation

Callout

Component Name

1

3? Reverse Clutch Apply Plate (Waved)

2

3? Reverse Clutch Plate (Qty: 3)

3

3? Reverse Clutch Plate Assembly (Qty: 3)

4

3? Reverse Clutch Backing Plate

5

3? Reverse Clutch Backing Plate Ring Retainer Ring

Reluctor Wheel and Piston Installation


Reluctor Wheel and Piston Installation

Callout

Component Name

1

3? Reverse Clutch Piston Dam Seal (Black)

2

3? Reverse Clutch Piston Inner Seal

3

3? Reverse Clutch Piston Inner (Reluctor) Seal (Orange)

4

3? Reverse Clutch Piston Return Spring Assembly

5

3? Reverse Clutch Piston

6

Input Shaft Speed Sensor Reluctor Wheel

7

Input Shaft Speed Sensor Reluctor Ring Retainer Ring

Caution:

Compress the reluctor wheel just enough to clear the retainer. Over compressing the reluctor wheel will break the alignment tab and the clutch housing.

Caution:

Regulate the air pressure to 276 kPa (40 psi) maximum. High pressure could cause the piston to over travel and damage the piston seals.

Procedure

Place the housing assembly onto the input shaft support inside the case. Apply shop air to the clutch fluid feed hole in the case to verify proper piston operation.

Special Tools

DT-47694 Piston Spring Compressor

For equivalent regional tools, refer to Special Tools.

4?? Clutch Plates Installation


4?? Clutch Plates Installation

Callout

Component Name

1

Reaction Carrier Hub Thrust Bearing Assembly

2

Reaction Carrier Hub Assembly

3

4?? Clutch Plate Assembly (Qty: 5)

4

4?? Clutch Plate (Qty: 5)

5

4?? Clutch Backing Plate

6

4?? Clutch Backing Plate Retaining Ring

Turbine Shaft Installation


Turbine Shaft Installation

Callout

Component Name

1

Turbine Shaft

2

Turbine Shaft Retainer Ring

Note:

Do not re-use the turbine shaft retainer ring.

Special Tools

GE 5586-A Snap Ring Pliers or equivalent

For equivalent regional tools, refer to Special Tools.

3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring Replacement (Gen 2)
3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring Replacement Callout Component Name Special Tools DT-46620 Seal Installer For e ...

3-5-Reverse and 4-5-6 Clutch Housing Disassemble (6T30/40/45/50 - Gen 2)
Table 1: Turbine Shaft, Reluctor Wheel and Piston Removal Table 2: 4?? Clutch Plate Removal Table 3: 4?? Clutch Piston Removal Table 4: Reluctor Wheel ...

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