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Transaxle Reassembly

NOTE: End play checks performed during TRANSAXLE DISASSEMBLY procedure must be rechecked at appropriate reassembly stage. For thrust washer, thrust bearing, bushing and seal installation direction and location during reassembly, refer to appropriate illustration. See Fig 1-Fig 5 .
  1. Install shift and park linkage components into case. Install final drive internal gear assembly into case. Align parking pawl with parking pawl actuator. Using snap ring remover or long screwdriver, install retaining ring into case. See Figure.
  2. Position transaxle with oil pan flange facing down. Ensure sun gear thrust bearing is installed into differential carrier. Install differential carrier sun gear. Step in sun gear must be pointing toward parking gear. Install parking gear. Install internal gear thrust bearing into differential carrier. Ensure bearing is positioned properly. Install sun gear shaft into differential carrier. See Figure. Install differential carrier into case.
  3. Install selective thrust washer and thrust bearing onto differential carrier. Install seal onto case extension. Install case extension onto transaxle case. Install and tighten 2 case extension bolts only until case extension is seated into case. DO NOT torque bolts.
  4. Position transaxle case with flange for case cover facing up. Install differential carrier internal gear thrust washer into case. Install forward band into case. Locate band onto forward band anchor pin. Position band apply pin in case opening.
  5. Install 1-2 support drum. Position 2-1 band on anchor pin. Install reaction sun gear and drum. Ensure sun gear and drum fully engage 1-2 support roller clutch. Check roller clutch for correct operation. See Figure.
  6. Install reaction carrier/sun gear thrust bearing onto reaction carrier. Install reaction carrier into transaxle case and rotate carrier so pinions engage reaction sun gear. Install thrust bearing and lube dam onto input carrier. Install input carrier into transaxle case and rotate carrier so pinions engage reaction carrier internal gear. See Figure.
  7. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch hubs must engage clutch plates. Install input clutch roller clutch and sprag assemblies into case using Final Drive/Clutch Installer (J-33381). DO NOT install 2nd clutch housing, thrust bearing or thrust washer at this time.
  8. Check input clutch housing end play. See INPUT CLUTCH HOUSING END PLAY CHECK  under TRANSAXLE DISASSEMBLY. Using feeler gauge, check clearance between thrust washer and end play gauge. Clearance must be .0-.006" (.0-.15 mm). If clearance is not as specified, use different thrust washer. See INPUT CLUTCH THRUST WASHER IDENTIFICATION  table. Remove input clutch assembly.
    INPUT CLUTCH THRUST WASHER IDENTIFICATION

    Washer ID No. Color Thickness - In. (mm)
    1 Orange/Green .114-.118 (2.90-3.00)
    2 Orange/Black .120-.124 (3.05-3.15)
    3 No Color .126-.130 (3.20-3.30)
    4 White .132-.136 (3.35-3.45)
    5 Blue .138-.142 (3.50-3.60)
    6 Pink .144-.148 (3.65-3.75)
    7 Brown .150-.154 (3.80-3.90)
    8 Green .156-.159 (3.95-4.05)
    9 Black .161-.165 (4.10-4.20)
    10 Purple .167-.171 (4.25-4.35)
    11 Purple/White .173-.177 (4.40-4.50)
    9. NOTE: This step has been revised due to ATRA TSB No. 579, dated November 2000.
  9. Check for damaged 2nd clutch and reverse reaction drum splines. Original 2nd clutch and reverse reaction drums have splines with 25 degree sides and have tendency to strip. New design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) has splines with 10 degree sides.
  10. Install reverse band into case, locating band on anchor pins. Install selective thrust washer and thrust bearing onto input clutch assembly. Install thrust bearing with large race facing down. Install 2nd clutch assembly onto input clutch assembly. Clutch plates must engage input clutch hub.
  11. Install final drive/clutch installer into assembled input and second clutch housing assemblies. Tighten threaded rod of final drive/clutch installer until rod is finger tight. Using final drive/clutch installer, lift input and second clutch housing assembly, and install input and second clutch housing assembly into case. See Figure. Ensure input clutch housing assembly is fully seated. Ensure second clutch housing is .500" (13 mm) above top of reverse band assembly.
  12. Install thrust washer onto driven sprocket support, and hold washer in position with petroleum jelly. Install driven sprocket support into case. See Figure. Ensure support is flush with or below case.
  13. Use petroleum jelly to hold thrust washer onto drive and driven sprockets. Assemble drive and driven sprockets into drive chain assembly as follows: If old drive chain is being reinstalled, assemble drive chain and sprockets with master link (Bronze) facing in same direction as removed. See DRIVE & DRIVEN SPROCKETS  under TRANSAXLE DISASSEMBLY. If NEW drive chain assembly is being installed, assemble drive chain and sprockets with master link facing upward.
  14. Install drive chain assembly and sprockets into case. Using slight rocking motion, may be required to work sprockets into place. Install input speed sensor reluctor wheel onto drive sprocket. See Figure. Perform DRIVE CHAIN (DRIVE LINK) STRETCH CHECK. See DRIVE & DRIVEN SPROCKETS  under TRANSAXLE DISASSEMBLY.
  15. Install 4th clutch shaft thrust washer onto driven sprocket. Insert 4th clutch shaft into transaxle case through driven sprocket. See Figure. Shaft must fully seat into input sun gear. Install drive chain lube scoop into case.
  16. Install fourth clutch apply plate over fourth clutch shaft assembly and into driven sprocket support with machined side towards driven sprocket. Install remaining 4th clutch plates, starting with composition plate and alternating with steel plates. Clutch plates should align in driven sprocket support.
  17. If necessary, pry out axle seal from case cover, and tap NEW seal into place. Install pistons and pins into case cover. Install springs into case cover. Install case cover gaskets. Install 4th clutch shaft and drive sprocket thrust washers onto case cover. See Figure.
  18. Install case cover onto transaxle case. Case cover lugs must align with tangs on 4th clutch plates. See Figure. Install case cover bolts. See CASE COVER BOLT SPECIFICATIONS . Tighten case cover bolts to specification. See TORQUE SPECIFICATIONS . Install oil pump drive shaft.
    CASE COVER BOLT SPECIFICATIONS

    Bolt No. (1) Diameter - In. (mm) Length - In. (mm)
    1 0.24 (6) 1.3 (32)
    2 0.24 (6) 1.6 (40)
    3 0.31 (8) 2.0 (50)
    4 0.24 (6) 1.2 (30)
    (1) For bolt location, refer to illustration. See Figure
    .
  19. Install drive link lube scoop into case. See Figure. Connect manual valve link to manual valve. See Figure. Install manual shift detent, and tighten bolt to specification. See TORQUE SPECIFICATIONS .
  20. Install 4 check balls into case cover. See Figure. Use petroleum jelly to hold check balls in position. Install 2 large check balls and 4 small check balls into control valve body. See Figure.
  21. Install solenoid screen/seal assemblies into spacer plate. Install case cover guide pin into case cover. Install valve body-to-spacer plate gasket, spacer plate and case cover-to-spacer plate gasket onto control valve body. Install bolts to hold spacer plate and gaskets onto control valve body. See Figure.
  22. Install control valve body onto case cover. Use case cover pin and turbine sleeve in case cover as guides. Ensure check balls do not drop out of control valve body during reassembly. Install fluid pressure manual valve position switch onto control valve body.
  23. Install control valve body bolts. See VALVE BODY BOLT SPECIFICATIONS  table. Finger tighten bolts to prevent cross-threading. Tighten bolts in a spiral pattern starting with bolts at center of control valve body. If bolts are tightened at random, valve bores may become distorted and prevent proper valve operation. Tighten valve body bolts to specification. See TORQUE SPECIFICATIONS .
  24. Install oil pump assembly onto control valve body. Install oil pump bolts in specified locations. See OIL PUMP BOLT SPECIFICATIONS  table. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install electronic components and wiring harness. Ensure wire connectors are installed in correct locations. See Figure.
    VALVE BODY BOLT SPECIFICATIONS

    Bolt No. (1) Diameter - In. (mm) Length - In. (mm)
    1 0.24 (6) 2.6 (65)
    2 0.24 (6) 2.4 (60)
    3 0.24 (6) 1.2 (30)
    4 0.24 (6) 1.8 (45)
    5 0.24 (6) 2.2 (55)
    6 0.24 (6) 3.7 (95)
    7 0.31 (8) 3.5 (90)
    8 0.24 (6) 0.8 (20)
    9 0.24 (6) 3.3 (85)
    (1) For bolt location, refer to illustration. See Figure
    .
    OIL PUMP BOLT SPECIFICATIONS

    Bolt No. (1) Diameter - In. (mm) Length - In. (mm)
    1 0.24 (6) 0.8 (20)
    2 0.24 (6) 3.7 (95)
    3 0.24 (6) 3.3 (85)
    (1) For bolt location, refer to illustration. See Figure
    .
  25. Check front differential carrier end play. See FRONT DIFFERENTIAL CARRIER END PLAY CHECK  under TRANSAXLE DISASSEMBLY. Install appropriate thrust washer on to input shaft and hold in position with petroleum jelly. See CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES  table. Install output shaft. Ensure output shaft snap ring locks into final drive. Tighten case extension bolts to specification. See TORQUE SPECIFICATIONS .
  26. Install side cover gasket and seal onto transaxle case. See Figure. Install case side cover. See Figure. Tighten side cover bolts to specification. See TORQUE SPECIFICATIONS .
    27. NOTE: 2-1 manual servo pipe should be installed in accumulator housing center hole, and lube oil pipe should be installed in right side hole. See Figure. Forward servo pipe cannot be installed in incorrect hole due to a larger pipe diameter.
  27. Install cover gasket to 2-1 manual band servo into case. Lubricate gasket with ATF. Install 2-1 manual band servo assembly into case. Ensure servo piston pin engages band. Install accumulator and cover assembly to 2-1 manual band servo into case. Install lube oil pipe into case at lube hole for differential carrier internal gear. Lock lube oil pipe retainer into case. Install cover bolts for 2-1 manual band servo. Install accumulator cover bolts and tighten bolts to specification. See TORQUE SPECIFICATIONS . See Figure.
  28. Install NEW oil filter seal, oil filter and pan gasket into case. Install oil pan and tighten bolts to specification. See TORQUE SPECIFICATIONS . Install forward and reverse servo return springs into proper servo bore. Assemble each servo, and then install into case. Install NEW oil seal ring onto each servo cover.
  29. Install forward servo cover and bolts. Install reverse servo cover and retaining ring. See Figure. Install vehicle speed sensor. Install "O" ring onto turbine shaft. Install torque converter.
CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES

Washer ID No. Color Thickness - In. (mm)
1 Orange .055-.059 (1.40-1.50)
2 White .059-.063 (1.50-1.60)
3 Blue .063-.067 (1.60-1.70)
4 Pink .067-.071 (1.70-1.80)
5 Brown .071-.075 (1.80-1.90)
6 Green .075-.079 (1.90-2.00)
7 Black .079-.083 (2.00-2.10)
8 Purple .083-.087 (2.10-2.20)
9 Purple/White .087-.091 (2.20-2.30)
10 Purple/Blue .091-.094 (2.30-2.40)
Fig 1: Identifying Thrust Washer Locations
G98E01884Courtesy of GENERAL MOTORS CORP.
Fig 2: Identifying Thrust Bearing Locations
G98H01885Courtesy of GENERAL MOTORS CORP.
Fig 3: Identifying Bushing Locations
G98J01886Courtesy of GENERAL MOTORS CORP.
Fig 4: Identifying Lip Seal Locations
G98B01887Courtesy of GENERAL MOTORS CORP.
Fig 5: Identifying "O"Ring & Seal Locations
G98D01888Courtesy of GENERAL MOTORS CORP.
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