vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Low and Reverse and 1-2-3-4 Clutch Housing Disassemble > < 3-5-Reverse and 4-5-6 Clutch Housing Disassemble - 6T40/45/50 - Gen 1

Astra J

3-5-Reverse and 4-5-6 Clutch Housing Assemble (6T40/45/50 - Gen 1)

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

3-5 Reverse Clutch Plates Installation



1891346



3-5 Reverse Clutch Plates Installation


Callout
Component Name

1
3-5 Reverse Clutch Apply Plate (Waved)

2
3-5 Reverse Clutch Plate (Qty: 3)

3
3-5 Reverse Clutch Plate Assembly (Qty: 3)

4
3-5 Reverse Clutch Backing Plate

5
3-5 Reverse Clutch Backing Plate Ring Retainer Ring
 

Reluctor Wheel and Piston Installation



1891348



Reluctor Wheel and Piston Installation


Callout
Component Name

1
3-5 Reverse Clutch Piston Dam Seal (Black)

2
3-5 Reverse Clutch Piston Inner Seal

3
3-5 Reverse Clutch Piston Inner (Reluctor) Seal (Orange)

4
3-5 Reverse Clutch Piston Return Spring Assembly

5
3-5 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 .
 

4-5-6 Clutch Piston Installation



1891354



4-5-6 Clutch Piston Installation


Callout
Component Name

1
4-5-6 Clutch Piston Inner Seal

2
4-5-6 Clutch Piston Outer Seal (Large) (Rounded)

3
4-5-6 Clutch Piston Outer Seal (Dark Blue) (Stepped)

4
4-5-6 Clutch Piston

Tip

•  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 .
 

4-5-6 Clutch Fluid Dam Installation



1891357



4-5-6 Clutch Fluid Dam Installation


Callout
Component Name

1
4-5-6 Clutch Piston Return Spring Assembly

2
4-5-6 Clutch Piston Fluid Dam Assembly

Tip
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
4-5-6 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. The 4-5-6 clutch dam retaining ring is not reusable, install a NEW retaining ring.
2. Leave the seal protector in place while installing the retaining 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

For equivalent regional tools, refer to Special Tools .
 

4-5-6 Clutch Plates Installation



1891361



4-5-6 Clutch Plates Installation


Callout
Component Name

1
Reaction Carrier Hub Thrust Bearing Assembly

2
Reaction Carrier Hub Assembly

3
4-5-6 Clutch Wave Plate

4
4-5-6 Clutch Apply Plate

5
4-5-6 Clutch Plate Assembly (Qty: 4)

6
4-5-6 Clutch Plate (Qty: 3)

7
4-5-6 Clutch Backing Plate

8
4-5-6 Clutch Backing Plate Retaining Ring
 

Turbine Shaft Installation



1891372



Turbine Shaft Installation


Callout
Component Name

1
Turbine Shaft

2
Turbine Shaft Retainer Ring

Tip
Do not re-use the turbine shaft retainer ring.

Special Tools

GE 5586-A   Circlip Pliers or equivalent

For equivalent regional tools, refer to Special Tools .
 

Low and Reverse and 1-2-3-4 Clutch Housing Disassemble > < 3-5-Reverse and 4-5-6 Clutch Housing Disassemble - 6T40/45/50 - Gen 1