Transaxle Reassembly
NOTE:
All selective snap ring and thrust washer measurements taken during disassembly must be rechecked at appropriate reassembly stage.
- Install manual shaft, detent lever assembly and parking pawl, if removed. Install drive sprocket support, transaxle input speed sensor and wiring harness. See Figure . Install torque converter seal.
- Install lo/reverse band and ensure anchor engages band. Install fretting ring with open end at bottom. Install oil cooler return fitting "O" ring to coast and forward clutch assembly. Using Forward/Coast Clutch Puller (J-39053), install coast and forward clutch assembly into case. See Figure . Ensure anchor holes in support align with holes in case.
- Install final drive internal gear with groove up. Install snap ring with open end in scavenge tube area. Rotate support counterclockwise against spline. See Fig 1 .
- Install reaction shell and 3rd clutch housing. Install input shaft selective washer and thrust bearing on 3rd clutch housing. See Figure
. Install 4th band and reverse clutch assembly. See Fig 2
. Ensure band pin seat engages servo pin. Install reverse clutch housing and thrust washer.
Courtesy of GENERAL MOTORS CORP.
- Install seal on drive sprocket support. Using Sizer (J-39064-2), size seal. Install backing plate, 2nd clutch plates, apply plate and waved plate.
- Place scavenge tube seal on driven sprocket support and install driven sprocket support. Install drive chain (in same direction as removed) to drive sprocket support. Tap sprockets until seated. Place thrust roller bearings on sprockets.
- To air check reverse, 2nd and 3rd clutches at drive sprocket support, go to next step. Install island gasket and case cover gasket. Install case cover allowing wiring harness connector to pass through opening in case cover. Install bolts in correct position and hand tighten only. See Fig 4 . Go to step 10).
- Using 40 psi (2.7 kg/cm2 ) of air pressure, air check clutches and servos. Reverse, 2nd and 3rd clutches may be checked at driven sprocket support. Coast and forward clutches may be checked through passage in lower case. See Fig 5 . To check Reverse clutch, 3rd clutch or 4th servo, fabricate an air checking plate. See Fig 6 .
- Trace template as shown. See Fig 6
. Using 3/8-1/2" thick aluminum or plastic plate, cut out an air checking plate to match template. Mark and drill holes in plate. Drill bolt holes .275" (7 mm) and air holes .157" (4 mm). Bolt plate to case. Air check clutches and 4th servo.NOTE: About 90-100 psi (6.2-6.9 kg/cm2 ) of air pressure are required to apply the 3rd clutch.
- Check input shaft end play. See Figure . Install Input Shaft End Play Fixture (J-39686) to front side of transaxle. Ensure "J" tab on fixture rests on input shaft. Mount Dial Indicator Post (J-25025-7A) and Dial Gauge (J-8001-3) to check end play. Push down on handle. End play should be .004-.034" (.10-.85 mm). Input shaft thrust washers size range is .089-.195" (2.27-4.97 mm) in increments of .012" (.30 mm).
- Tighten case cover bolts and studs in a criss-cross pattern. Install 2 check balls. See Fig 4 . Install upper valve body. See Fig 7 . Tighten bolts starting with center ones and working to outside ones. Install side filter.
- Install TCC/VCC solenoid and transaxle pressure control solenoid. Install oil pump assembly. Tighten bolts starting with center ones and working to outside ones. Install oil pan and tighten bolts in a star pattern. Install 4th servo. See Fig 3 . Ensure tab on servo piston aligns with slot in case (some models).
- Using a long thin piece of .025" (.60 mm) shim stock, slide lo/reverse band into position. Install lower valve body and channel plate. See Fig 8 . Install bolts and tighten by hand. Remove shim stock.
- Install oil transfer plate and hand tighten bolts. See Fig 8 . Connect wiring harness and manual valve. Tighten channel plate and oil transfer plate bolts in a criss-cross pattern. Install scavenge screens. See Fig 3 . Install pan gasket and tighten bolts in a star pattern.
- Assemble and install final carrier, output shaft and differential carrier. See Fig 3 . Engage parking pawl to hold final drive unit. Tighten differential carrier bolts.
- Install scavenge tube and seal. Install selective thrust washer and roller thrust bearing onto output shaft. See Fig 3 . Install extension housing and hand tighten bolts.
- Mount Dial Indicator Post (J-39687) and Dial Gauge (J-8001-3) to check end play. Pry up on speed sensor rotor through speed sensor hole. End play should be .006-.025" (.15-.65 mm). See Figure .
- If necessary, adjust end play with selective final drive-to-case thrust washer. See FINAL DRIVE-TO-CASE SELECTIVE THRUST WASHER SIZES . Tighten extension housing bolts. Install oil cooler return fitting to forward and coast clutch support. Install axle seals, oil pump drive shaft, torque converter and vehicle speed sensor.
FINAL DRIVE-TO-CASE SELECTIVE THRUST WASHER SIZES
| Washer ID Color | Thickness: In. (mm) |
|---|---|
| Orange | .137-.141 (3.49-3.59) |
| White | .131-.136 (3.35-3.46) |
| Blue | .126-.130 (3.21-3.32) |
| Pink | .120-.125 (3.07-3.18) |
| Brown | .115-.119 (2.93-3.04) |
| Green | .110-.114 (2.79-2.90) |
| Black | .104-.109 (2.65-2.77) |
LEGEND FOR FIGURE 42
| Item No. | Component |
|---|---|
| 1 | Oil Pump Shaft Thrust Washer |
| 2 | Stator Shaft Bushing |
| 3 | Thrust Bearing Assembly |
| 4 | Sprocket Bearing |
| 5 | Converter Hub Bushing |
| 6 | Thrust Bearings |
| 7 | Forward Clutch Housing Thrust Bearing |
| 8 | Housing Bushing (Small) |
| 9 | Forward Clutch Housing/Parking Gear Thrust Bearing |
| 10 | Housing Bushing (Large) |
| 11 | Forward Clutch Housing/Parking Gear Thrust Bearing |
| 12 | Sun Gear Thrust Bearing |
| 13 | Differential Thrust Washer (Left) |
| 14 | Differential Thrust Washer (Right) |
| 15 | Differential Carrier Selective Thrust Washer |
| 16 | Thrust Bearing |
| 17 | Extension Housing Bushing |
| 18 | Shaft Support Bushing (Right) |
| 19 | Oil Transfer Sleeve |
| 20 | Shaft Support Bushing (Left) |
| 21 | Input Flange Bushing |
| 22 | Coast Clutch Hub Thrust Washer |
| 23 | Hub Bushing |
| 24 | Input Internal Gear Flange Thrust Washer |
| 25 | Reaction Sun Gear Bushing |
| 26 | 3rd Hub Thrust Washer |
| 27 | Input Shaft Oil Transfer Sleeve |
| 28 | Driven Sprocket Support Selective Thrust Washer |
| 29 | Reverse Clutch Housing Bushing (Small) |
| 30 | 2nd Clutch Outer Race Washer |
| 31 | Reverse Clutch Housing Bushing (Large) |
| 32 | Reverse Clutch Support Thrust Washer |
| 33 | Input Shaft Bushing |
| 34 | Oil Transfer Sleeve |
| 35 | Forward Clutch Support Parking Gear Thrust Bearing |
LEGEND FOR FIGURE 43
| Item No. | Component |
|---|---|
| 1 | Oil Filter Seal |
| 2 | Turbine Shaft Seal |
| 3 | Drive Sprocket Seal |
| 4 | Drive Sprocket Seal Ring |
| 5 | Transaxle Side Cover Gasket |
| 6 | Converter Hub Seal |
| 7 | Oil Pump Shaft "O" Ring |
| 8 | 2nd Clutch Piston |
| 9 | Reverse Clutch Seal |
| 10 | Driven Sprocket Support Seal |
| 11 | 3rd Clutch Piston |
| 12 | Forward Clutch Piston Seal |
| 13 | Coast Clutch Piston |
| 14 | Oil Cooler Fitting "O" Ring |
| 15 | Extension Housing Seal |
| 16 | Final Drive Sun Gear Seal |
| 17 | Axle Seal |
| 18 | Forward/Coast Clutch Support Seals (3) |
| 19 | Vehicle (Output) Speed Sensor |
| 20 | Lo/Reverse Servo Seal |
| 21 | Reverse Accumulator Seal |
| 22 | Forward Accumulator Seal |
| 23 | 1-2 Accumulator Seal |
| 24 | 3-4 Accumulator Seal |
| 25 | 4th Servo Cover Seal |
| 26 | 4th Servo Piston Seal |
| 27 | Axle Seal |
| 28 | 2-3 Accumulator Seal |
| 29 | "O" Ring Seal |