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 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. 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. 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 ...

Other materials:

Windshield Wiper/Washer
Sedan Hatchback The windshield wiper/washer lever is on the right side of the steering column. Move the lever to one of the following positions: HI: Use for fast wipes. LO: Use for slow wipes. Hatchback Shown, Sedan Similar INT: Move the lever up to INT for intermittent wipes, then turn ...

Special Tools
Illustration Tool Number/ Description CH-161-B DT-161-B KM-161-B J-22888-20A Bearing Puller CH-804 CH-49692 MKM-804 Tensioner CH-39570 J-39570 ...

Secondary Air Injection System Description
The Secondary Air Injection System aids in the reduction of hydrocarbon exhaust emissions during a cold start. This occurs when the start-up engine coolant temperature (ECT) is between −10 to +56°C (14?E33°F), the intake air temperature (IAT) is greater than −10°C (14°F) and it ...

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