LEMON Manuals: Even more car manuals for everyone
Home >> Saturn >> 2005 >> Vue Red Line, FWD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - 5AT - Introduction & Repair Instructions >> Repair Instructions >> Transmission Case Assembly Installation >> Installation Procedure

Installation Procedure

    Fig 1: Transmission Case Housing, Housing Gasket & Locating Pin
    GM1359036Courtesy of GENERAL MOTORS CORP.
  1. Install two 14 x 25 mm transmission case locating pins (126) into the torque converter housing (150).
  2. Install a new torque converter housing gasket (68) into the torque converter housing (150).
  3. If necessary, remove the reverse idler gear access hole plug (102) and sealing washer (103) from the rear of the transmission case assembly (31).
  4. Lower the transmission case housing assembly (31) onto the torque converter housing (150).
    5. Fig 2: Rotating Reverse Idler Gear To Engage Reverse Gear With Reverse Driven Gear & 5th/Reverse Drive Gear
    GM1206256Courtesy of GENERAL MOTORS CORP.
  5. Wrap a screwdriver tip with tape to prevent damage to the reverse idler gear teeth.
  6. Using the screwdriver, rotate the reverse idler gear (527) to engage the reverse gear with the reverse driven gear (512) and the 5th/reverse drive gear.
    7. Fig 3: Expanding Output Shaft Retaining Ring Using Pliers To Install Transmission Case Housing
    GM1206260Courtesy of GENERAL MOTORS CORP.
  7. Using snap ring pliers, expand the output shaft retaining ring (513) and continue to install the transmission case housing (31) partially onto the output shaft rear bearing (514).
  8. Release the snap ring pliers, and carefully push down on the transmission case (31) until it bottoms out on the torque converter housing.
  9. Visually inspect that the output shaft retaining ring (513) has snapped into place in the retaining ring groove in the output shaft rear bearing (514).
    10. Fig 4: Installing Torque Converter Housing Bolts
    GM1206266Courtesy of GENERAL MOTORS CORP.
  10. Clean all case mounting bolts of any grease or oil.
  11. Install a M10 x 1.25 x 50 mm torque converter housing bolt (92) in the correct location.
  12. Install 5 M10 x 1.25 x 70 mm torque converter housing bolts (91) in the correct location.
  13. Install a M10 x 1.25 x 80 mm torque converter housing bolt (107) in the correct location.
  14. Install 14 M10 x 1.25 x 90 mm torque converter housing bolts (106) in the correct location, include the transmission wire harness bracket (108).
  15. Install a M10 x 1.25 x 100 mm torque converter housing bolt (90) in the correct location.
  16. Install 2 M10 x 1.25 x 140 mm torque converter housing bolts (89) in the correct location, include the transmission lift bracket (88).
    17. Fig 5: Tightening Transmission Case Assembly Bolts In Sequence
    GM1347217Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  17. Tighten the case bolts in the sequence shown.

    Tighten: 

    • Tighten the upper case bolts (1 and 3) to 39 N.m (29 lb. ft.).
    • Tighten 22 case bolts (2 and 7-24) to 44 N.m (33 lb. ft.).

  18. Rotate the transaxle assembly to the installed or upright position.
    19. Fig 6: Mainshaft, Washer & Retaining Nut
    GM1206272Courtesy of GENERAL MOTORS CORP.
  19. Lubricate both sides of a 29 x 40 x 3.9 mm mainshaft washer (109) with automatic transmission fluid.
  20. Install the NEW mainshaft washer (109) on the mainshaft (640) with the marked side up as shown.
  21. Install the original mainshaft retaining nut (110) on the mainshaft (640) and hand tighten.
    22. Fig 7: DT 46435, DT 46434, Mainshaft Splines & Nuts
    GM1206268Courtesy of GENERAL MOTORS CORP.
  22. Install DT 46435  (2) through the hole in DT 46434  (1). See Special Tools .
  23. Install DT 46434  onto the mainshaft splines and at the same time secure DT 46435  (2) into the lock hole in DT 46238  (3) as shown. See Special Tools .
  24. Tighten the original mainshaft nut (110) in order to seat the new mainshaft washer (109).

    Tighten:  Tighten the nut to 178 N.m (132 lb. ft.).

  25. Remove the original mainshaft nut (110).
  26. Install a new mainshaft nut (110).

    Tighten:  Tighten the nut to 178 N.m (132 lb. ft.).

    27. Fig 8: Staking Mainshaft Nut Into Mainshaft Using A Punch
    GM1206276Courtesy of GENERAL MOTORS CORP.
  27. Using a 3.5 mm (9/64 in) punch (1), stake the new mainshaft nut (110) into the mainshaft (641).

    Specification:  Stake the nut to a depth of 0.7-1.3 mm (0.03-0.05 in).

    28. Fig 9: Mainshaft Rear Case Cover Locating Pin, O-Ring Seal & Transfer Tube
    GM1347220Courtesy of GENERAL MOTORS CORP.
  28. Install a mainshaft rear case cover locating pin (114) on the transmission case (31).
  29. Install a mainshaft lube transfer tube (113) on the transmission case (31).
  30. Install a mainshaft case rear cover O-ring seal (99) on the mainshaft case rear cover (98).
  31. Install the mainshaft case rear cover (98) onto the transmission case (31).
  32. Install 3 M8 x 1.25 x 21 mm mainshaft case rear cover bolts (97) on the transmission case (31) and tighten.

    Tighten:  Tighten the bolts to 19 N.m (14 lb. ft.).

    33. Fig 10: Output Shaft Rear Access Cover, Bolts, O-Ring Seal & Transmission Case
    GM1347221Courtesy of GENERAL MOTORS CORP.
  33. Install a 28 x 2.2 mm O-ring seal (96) and the output shaft rear access cover (95).
  34. Install the output shaft rear access cover (95).
  35. Install the M6 x 1.25 x 20 mm output shaft rear access cover bolts (94).

    Tighten:  Tighten the bolts to 12 N.m (106 lb. in.).

    36. Fig 11: Reverse Idler Gear Access Hole Plug, Seal & Transmission Case
    GM1347229Courtesy of GENERAL MOTORS CORP.
  36. Apply threadlocker GM P/N 12345382 (Canada P/N 10953489) to the threads of the 20 mm reverse idler gear access hole plug (102).
  37. Install a reverse idler gear access hole plug 20 mm sealing washer (103) on the reverse idler gear access hole plug (102).
  38. Install the reverse idler gear access hole cover plug (102).

    Tighten:  Tighten the cover plug to 49 N.m (36 lb. ft.).

scientia non olet · About LEMON Manuals