Daewoo Korando. Manual — part 265

AUTOMATIC TRANSMISSION 5A-103

11. Assemble the piston return spring to the piston, and fit the

spring retainer over the spring.

Notice

The wire diameter of this spring is 4.3 mm.

12. Using special tool No. 0555-331899, compress the spring

sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then
remove the tool.

13. Check the C1 piston check valves are not damaged and

are free to move, and that the cylinder feed orifices are
clear of obstructions.

14. Lubricate the’0’rings with automatic transmission fluid and

fit them to their respective grooves.

Notice

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

15. Position the cylinder with the C1 cavity upwards. Install the

piston into the cylinder until the outer diameter of the piston
enters the inner diameter of the cylinder.

16. Install the spring and spring retainer onto the piston.

Notice

The wire diameter of this spring is 5.26 mm.

17. Using special tool No. 0555-331899, compress the spring

sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then
remove the tool.

18. Install the C2 wave washer into the cylinder with the crest

of one wave covering one of the bleed orifices in the C2
piston.

19. Measure and record the thickness of the flange of the C2

sleeve. Refer to figure 8.25.

20. Install the C4 clutch plates and wave washer into the C2

actuating sleeve, with the rounded edge of the steel plates
down, in the following sequence:

l

Steel plate (selective)

l

Friction disc

l

Steel plate

l

Friction disc

l

Steel plate

l

Friction disc

l

Steel plate

l

Wave washer

5A-104 AUTOMATIC TRANSMISSION

Figure 8.25 - C4 Clutch Pack Clearance

AUTOMATIC TRANSMISSION 5A-105

21. Holding the cylinder horizontal, install the sleeve and clutch

plate assembly into the cylinder, with the crest of one wave
of the washer In line with one of the holes in the outside of
the cylinder, until the sleeve contacts the C2 wave washer.

22. Check the C4 clutch pack clearance using special tool No.

0555-331900. Refer to figure 8.25.

Notice

With the C2 wave spring compressed, and the clutch Pack
supporting a 2 k9 weight, the dimension from the underside
of the C2 pressure plate to the selective steel is to be
between 1.4- 1.8 mm. If the clutch is to be gauged from
the top of the pressure plate, then the dimension is to be
the actual thickness of the pressure plate plus 1.4-1.8 mm.

23. Use selective plates to achieve the correct specification. If

new friction plates are being fitted, remove the clutch pack
and soak the friction plates in ATF for a minimum of 5
minutes prior to reassembly.

Notice

The clutch pack clearance must be taken before the
elements are soaked in Automatic Transmission Fluid
(ATF).

24. Reassemble the sleeve and clutch pack into the cylinder.

Observe the alignment of the wave washer to the hole in
the cylinder.

25. Install the C2 clutch plates in the cylinder in the following

sequence:

l

Friction disc

l

Steel plate

l

Friction disc

l

Steel plate

l

Steel plate - 0574-000001, 0574-000003,

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

0574-000021, or friction disc -0574-000002

l

Steel plate (selective)

l

Friction disc

l

Steel plate (selective)

l

Friction disc

5A-106 AUTOMATIC TRANSMISSION

29. Align the tangs and fit the nylon thrust washer onto the

C4 hub. Refer to figure 8.27.

30. Align and fit the C4 hub to the C2 clutch and the OWC

assembly.

31. Check the rotation of the C2 hub. While holding the

C4 hub, the C2 hub should rotate in the clockwise
direction and lockup in the anti-clockwise direction when
viewed from the C2 hub. Refer to figure 8.27.

Figure 8.27 - C2 - Hub Rotation

32. Apply petroleum jelly to the No. 5 thrust bearing and fit

it to the C4 hub. Refer to figure 8.19.

33. Remove the C2 clutch plates from the clutch cylinder.

34. Fit the thrust plate over the cylinder inner hub. Refer

to figures 8.24 and 8.19.

35. Engage the C2/C4 clutch hub assembly in the C4 clutch

plates.

36. Install the C2 clutch plates.

37. Install the C3 hub and secure it with the circlip, ensuring

that the circlip is firmly seated in its groove.

Refer to figure 8.32.

Figure 8.26 - Typical C2 Clutch Pack Clearance

26. Check the clutch pack clearance using only the weight

from tool No.0555-331900. Refer to figure 8.26.

Notice

With the clutch pack supporting a 2 kg weight, the
dimension from the C3 clutch hub locating step to the
friction plate is to be between 0.80-1.05 mm.

27. Use selective plates to achieve the correct specification.

If new friction plates are being fitted, remove the clutch
pack and soak the friction plates in ATF for a minimum
of 5 minutes prior to reassembly.

Notice

The clutch pack clearance must be taken before the
elements are soaked in ATF.

28. Lubricate and fit the 3-4 OWC and end caps to the C2

hub.