Daewoo Korando. Manual - part 266

AUTOMATIC TRANSMISSION 5A-107

C3 Clutch and Reverse Sun Gear Assembly

To assemble the C3 clutch and reverse sun gear assembly
(refer to figure 8.28), proceed as follows.

1. Check the orifices in the cylinder are clear of obstructions.

2. Check the C3 cylinder bush outside diameter and the

centre support inside diameter are in good condition and
not damaged. Coat the sealing rings with automatic
transmission fluid and fit into the C3 cylinder grooves.

3. Check the reverse sun gear splines, grooves and thrust

face for condition. Coat the ‘O’ ring with automatic
transmission fluid and fit it to the groove of the reverse
sun gear.

4. Install the reverse sun gear in the C3 cylinder, ensuring

that the ‘O’ ring compression is adequate but not
excessive.

Notice

‘O’ rings must not be twisted in the grooves.

5. Coat the C3 piston ‘O’ rings with automatic transmission

fluid and fat the small ‘O’ ring onto the inner ring and the
large ‘O’ ring onto the outer ring of the C3 piston.

6. Check that the bleed orifices of the piston are clean and

clear of obstructions.

7. Install the C3 piston in the cylinder until the outside

diameter of the piston enters the inside diameter of the
cylinder.

Notice

Take care not to cut the ‘O’ ring.

8. Assemble the spring and spring retainer on the piston.

Using tool No. 0555-331899 compress the spring
sufficiently to enable the installation of the retaining circlip,
ensuring that the circlip is firmly seated in the groove, and
remove the tool.

9. Fit the C3 wave plate to the C3 piston face, ensuring that

one crest of the wave plate of the C3 piston face is aligned
over one of the piston orifices.

10. Assemble the clutch plates and discs into the cylinder in

the following sequence :

Steel plate

Friction disc

Steel plate

Steel plate - 0574-000001, 0574-000003,

0574-000004,0574-000005,0574-000020,

0574-000021, or friction disc -0574-000002

Steel plate (selective)

Friction disc

Steel plate (selective)

Friction disc

11. Align and fit the pressure plate with the counterbore facing

away from the clutch plates.

Figure 8.28 - C3 Clutch and Reverse Sun Gear

5A-108 AUTOMATIC TRANSMISSION

12. Install the circlip.

13. Check the C3 clutch clearance (refer to figure 8.29) using

special tool No.0555-331900 in the following manner
(weight only).

a. Place the weight on the pressure plate and measure

the distance from the end of the cylinder to the top of
the pressure plate.

b. Record this figure.

c. Remove the weight.

d. Lift the pressure plate up against the circlip and

measure the distance from the end of

the cylinder to the top of the pressure plate.

e. Record this figure.

Subtract the second reading from the first reading to
obtain the clutch pack clearance.

Notice

With the clutch pack supporting a weight of 2 kg, the
clearance between the snap ring and the top of the
pressure plate is to be between 1.20-1.45 mm.

14. If new friction plates are being fitted, remove the clutch

pack and soak the friction elements in automatic
transmission fluid for a minimum of five minutes prior to
reassembly.

Notice

The clutch pack clearance must be taken before the
elements are soaked in automatic transmission fluid.

Figure 8.29 - Typical C3 Clutch Assembly

Clearance

AUTOMATIC TRANSMISSION 5A-109

Forward Sun Gear and C3 Clutch Pack Assembly

To assemble the forward sun gear and C3 clutch pack assembly
(Refer to figure 8.30), proceed as follows:

1. Fit the No. 7 needle thrust bearing assembly over the forward

sun gear, ensuring that the thrust washer is between the
bearing and the sun gear.

2. Lubricate the thrust plate with petroleum jelly and fit the

thrust plate onto the reverse sun gear.

Refer to figure 8.33.

3. Align and fit the C3 clutch assembly over the forward sun

gear.

4. Lubricate the No. 6 needle thrust bearing with petroleum

jelly and fit it to the thrust plate. Ensure the lugs on the
outside diameter of the bearing fit in the thrust plate
counterbore.

Refer to figure 8.19.

5. Align and fit the plastic thrust washer to the thrust plate with

petroleum jelly.

Refer to to figures 8.19.

6. Install the assembly over the forward sun gear shaft against

the No.6 thrust bearing.

Refer to figure 8.19.

7. Place the assembly to one side.

Figure 8.30 - Typical forward Sun Gear add C3 Clutch Assembly

5A-110 AUTOMATIC TRANSMISSION

C1 Clutch Overdrive Shaft and Input Shaft
Assembly

Notice

1. Ensure that the snap rings are fitted correctly.

2. Check pistons for cracks, especially the C1 piston.

3. Do not mix clutch piston return springs.

4. If the C1/C2 clutch packs separate from the C3 clutch pack,

make sure the No. 6 bearing doesn’t drop out of the bearing
retainer.

To assemble the C1 clutch overdrive shaft and input shaft
assembly, proceed as follows:

1. Check the overdrive shaft grooves for any defect.

2. Coat the sealing rings, large and small, with petroleum jelly

and fit them to the overdrive shaft. The sealing rings may
be held in place with a small amount of petroleum jelly.

3. Assemble the clutch plate and disc into the cylinder in the

following sequence:

steel plate

friction disc

steel plate

friction disc

steel plate

steel plate - 0574-GOOGOl, 0574-000003,

0574-000004, 0574-000005, 0574-000020,

0574-000021, or friction disc -0574-000002

steel plate (selective)

friction disc

steel plate (selective)

friction disc

4. Check the clutch pack clearance using special tool No.0555-

331900. Refer to figure 8.31.

Use selective plates to achieve the correct specification.

Notice

The clutch pack supporting a 2 kg weight, the dimension
from the input shaft locating stop to the friction disc must
be 0.70-0.90 mm.

5. If new friction plates are being fitted, remove the clutch pack

and soak the friction elements in automatic transmission
fluid for a minimum of five minutes prior to assembly.

Notice

The clutch pack clearance must be taken before
elements are soaked in automatic transmission fluid.

6. Check the fit of the C1 clutch hub on the overdrive shaft. If

it is loose, the hub and shaft assembly must be replaced.

Figure 8.31 - Typical C1 Clutch Assembly

Clearance

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