Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET1994SUBURBAN K2500, 5.7 KREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONAUTOMATIC TRANSAUTOMATIC TRANSMISSION - OVERHAUL & TESTING - 4L80ECOMPONENT DISASSEMBLY & REASSEMBLYDIRECT CLUTCH ASSEMBLYREASSEMBLY
1994 Chevrolet Suburban K2500, 5.7 K
Direct Clutch Assembly: Reassembly
1994 Chevrolet Suburban K2500, 5.7 KSECTION Reassembly
- Reassemble intermediate sprag clutch. See Fig 1. Install new spiral snap ring. Ensure intermediate sprag rotates clockwise only. See Fig 2.
- Using Clutch Piston Installers (J-21362 and J-38732), install piston into direct clutch housing. Reassemble direct clutch. Direct clutch uses 5 steel plates, 5 composition plates and one dished plate. See Figure and Fig 3.
- Apply 80 psi (550 kPa) of air to the reverse port. See Fig 4. Air should bleed through direct port. Apply air pressure to direct port. Ensure piston seals do not leak. Direct clutch piston should move .121-.186" (3.07-4.72 mm).
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.