Vauxhall Workshop Service and Repair Manuals

Direct Clutch, Overhaul

Remove snap ring.

Remove backing plate and clutch plates (steel and lined) from clutch housing - see also "Technical Data".

Remove inner snap ring.

Remove spring assembly with waved springs and underlying piston.

Check seal ring in clutch housing for wear and damage, if necessary replace.

Note: Sealing lip must point upwards.

Check inner and outer piston seal ring for wear and damage, if necessary replace.

Note: Sealing lips must point away from piston head.

Single Parts of Direct Clutch

 1      Clutch housing

 2      Outer piston seal ring

 3      Seal ring in clutch housing

 4      Inner piston seal ring

 5      Direct clutch piston

 6      Spring assembly with waved spring

 7      Snap ring

 8      Clutch plate (steel)

 9      Clutch plate (lined)

10     Backing plate

11     Snap ring

Check all parts of direct clutch for wear and damage, if necessary replace by new parts.

Insert piston in clutch housing, in doing so coat seal rings with transmission fluid.

Note:    When inserting piston, turn carefully past grooves in snap rings in order to avoid damaging outer piston ring.

Insert spring assembly with waved springs and install inner snap ring.

Insert clutch plates (steel and lined) and backing plate and install with snap ring. In doing so, immerse clutch plates in transmission fluid.

Put together forward clutch and direct clutch.

Note:    Position direct clutch over input shaft of forward clutch and turn clutch plates of direct clutch to thread them into splines of forward clutch.

If assembly fits correctly, measurement "X" should be 35.8 mm/1.41 in.