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Transaxle Reassembly

NOTE: Coat all oil sealing rings, clutch discs, clutch plates, rotating parts and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cut outs and are installed correctly in groove. If a worn bushing is to be replaced, replacement must be made with subassembly containing that bushing. Check thrust bearings and races for wear or damage. Use petroleum jelly to hold parts in place. Replace parts as necessary. Soak clutch plates and brake band in ATF for 2 hours or more prior to installation.
NOTE: For thrust washer and bearing locations, refer to illustration. See Fig 8 .
CAUTION: Do not exceed 57 psi (4 kg/cm2 ) when applying air pressure to transaxle components.
  1. Install magnets on oil reserver plate. Install plate on converter housing. Install lubrication tube. Use soft-faced hammer to tap tube in place. Install tube hold-down clamp. Install spring, underdrive brake accumulator piston and cover. See Fig 1 .
  2. Install underdrive brake accumulator bracket, spring guide sleeve, spring and bolts. Install new seal rings on underdrive clutch drum support. Install underdrive one-way clutch. Install one-way clutch outer race retainer. See Fig 2 .
  3. Install snap ring. Align brake band with anchor bolt and install. Install anchor bolt and tighten to specification. See TORQUE SPECIFICATIONS  .
  4. Install spring, underdrive brake piston, cover and snap ring. Apply air pressure to appropriate fluid passage and measure underdrive brake piston stroke. See Fig 3 .
  5. Install counterdrive gear into transaxle case. Install snap ring. Install thrust washer and underdrive clutch drum. Check underdrive one-way clutch operation. Ensure underdrive clutch drum turns counterclockwise and locks clockwise.
  6. Install thrust washer. Install thrust bearing to rear side of underdrive planetary gear. Install underdrive planetary gear assembly. See Fig 4 . Ensure counterdrive and counterdriven gears rotate smoothly.
  7. Install thrust washer and bearing, with bearing facing up. Install lubrication tube. Install oil reserver plate. Install oil filter. Install transaxle case plate on edge of case. Install parking lock pin. Install cam plate, detent spring and parking lock rod. Install detent spring bolts finger tight.
  8. Install parking lock pawl. Place spring on parking lock pawl shaft and install in transaxle case. See Fig 5 . Install manual valve lever. Connect parking lock rod to manual valve lever. Place detent lever on manual valve lever. Tighten detent spring bolts.
  9. Install differential in case. Install new apply seal in transaxle case, near edge of ring gear. Apply sealer to transaxle case. Install converter housing to transaxle case. Install case bolts and tighten to specification. See TORQUE SPECIFICATIONS  .
  10. Install drain plug with new gasket. Turn assembly over. Place thrust bearing and race on front planetary ring gear flange. Install front planetary ring gear flange and one-way clutch assembly. Ensure ring gear turns counterclockwise and locks clockwise.
  11. Install low/reverse clutch pack. See Figure . Install snap ring. Using dial indicator, measure low/reverse clutch piston stroke. See Fig 6 . Apply air pressure to fluid passage on back of transaxle case. Ensure no air leakage is present. Piston stroke should be .069-.100" (1.75-2.55 mm).
  12. Install thrust washer. Install planetary gear and thrust washer. Install planetary sun gear and thrust washer into forward/direct clutch. Place thrust bearing on planetary sun gear. Install rear planetary ring gear and thrust washer into forward/direct clutch. Place thrust bearing on rear planetary ring gear. Install forward/direct clutch assembly.
  13. Install lubrication apply tubes. Install tube clamps. Install thrust bearing and race on back of forward/direct clutch drum. Install new apply seals. See Figure . Ensure thrust washer is installed on rear case drum support. Apply sealant to rear case. Install rear case and tighten bolts to specification.
  14. Install brake hub and one-way clutch assembly into oil pump. Install oil pump over input shaft with transaxle in horizontal position. Ensure input shaft has free play before tightening oil pump bolts. Install and tighten oil pump bolts.
  15. Using dial indicator, measure input shaft end play. End play should be .005-.035" (.37-.90 mm). See Fig 7 . Install valve body apply seals. See Figure .
  16. Install valve body. Connect manual valve connecting rod to manual detent lever. Install 7 valve body bolts and tighten in crisscross pattern. Install suction cover located at end of valve body assembly. Install solenoid wire harness. Connect solenoid connectors.
  17. Apply sealant to valve body cover and install. Install converter housing cover. Install TFT sensor. Install TFT sensor protector bracket. Install ISS and OSS sensors. Connect wire harness to TFT, ISS and OSS sensors.
  18. Install PNP switch. Install stud bolt and bolt. Finger tighten bolts. Install nut and washer on manual valve shaft. Tighten nut to specification. Place shift lever in "N" position. Align neutral basic line on PNP switch with flat on manual detent lever. Tighten PNP switch bolts. Install torque converter.
Fig 1: Installing Underdrive Brake Accumulator Piston
G00053915Courtesy of DAEWOO MOTOR AMERICA, INC.
Fig 2: Installing Underdrive One-Way Clutch Outer Race Retainer
G00053916Courtesy of DAEWOO MOTOR AMERICA, INC.
Fig 3: Identifying Underdrive Brake Piston Fluid Passage
G00053917Courtesy of DAEWOO MOTOR AMERICA, INC.
Fig 4: Installing Underdrive Planetary Gear Assembly
G00053918Courtesy of DAEWOO MOTOR AMERICA, INC.
Fig 5: Installing Parking Lock Pawl Assembly
G00053920Courtesy of DAEWOO MOTOR AMERICA, INC.
Fig 6: Checking Low/Reverse Clutch Piston Stroke
G00053919Courtesy of DAEWOO MOTOR AMERICA, INC.
Fig 7: Checking Input Shaft End Play
G00053921Courtesy of DAEWOO MOTOR AMERICA, INC.
Fig 8: Identifying Thrust Washer & Bearing Locations
G00053914Courtesy of DAEWOO MOTOR AMERICA, INC.
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