151-200

Transmission Overhaul Procedure Continued





151. Install the 41st and reverse brake plates (3), 4 brakes discs (1) and the flange (2) in the order shown into the transaxle case.
152. Using a screwdriver, install the snap ring.





Important: While applying 392 kPa (57 psi) of compressed air, measure the pack clearance. The pack clearance should be within 0.806 - 1.206 mm (0.0317 - 0.0475 inch). If the pack clearance is not as specified, install a new flange.

There are 4 thicknesses available, 3.4 mm (0.134 inch), 3.6 mm (0.142 inch), 3.8 mm (0.150 inch), 4.0 mm (0.157 inch).

153. Using a dial indicator, measure the pack clearance using compressed air.





154. Install the front planetary sun gear and roller bearing on the planetary gear assembly.





155. Install the outer race retainer to the 1 way clutch No.2.





156. Install the 1 way clutch No. 2 and the 2nd brake piston assembly to the rear planetary gear assembly.





157. Install the thrust bearing race No.2, planetary gear rear needle roller bearing and the thrust bearing race No.1 to the rear planetary gear assembly.





158. Install the rear planetary gear assembly in the transaxle case.

Important: Align the oil hole (1) of the 2nd brake piston assembly with the oil hole (1) in the transaxle case, then install the assembly into the transaxle case.

159. Using a screwdriver, install the snap ring.





160. Check that the rear planetary gear assembly turns freely counterclockwise (1) and locks clockwise (2).





161. Install the 2nd brake piston sleeve in the transaxle case.





162. Install the 3 2nd brake discs (1), 3 2nd brake plates (3) and the flange (2) in the order shown into the transaxle case.
163. Using a screwdriver, install the snap ring into the transaxle case.





Important: While applying 392 kPa (57 psi) of compressed air, measure the pack clearance. The pack clearance should be within 0.847 - 1.247 mm (0.0333 - 0.0491 inch). If the pack clearance is not as specified, install a new flange.

There are 4 thicknesses available, 3.0 mm (0.118 inch), 3.2 mm (0.126 inch), 3.4 mm (0.134 inch), 3.6 mm (0.142 inch).

164. Using a dial indicator, measure the pack clearance of the 2nd brake using compressed air.





165. Using a screwdriver, install the 2nd coast and overdrive brake flange hole snap ring into the transaxle case.





166. Install the thrust washer No.2 on the rear planetary gear assembly.
167. Install the 1 way clutch assembly on the rear planetary sun gear assembly.





168. Hold the rear planetary sun gear (3) and turn the 1 way clutch assembly. The 1 way clutch assembly should turn freely clockwise (2) and should lock counterclockwise (1).





169. Install the rear planetary sun gear thrust roller bearing and washer to the rear planetary sun gear.





170. Install the rear planetary sun gear assembly.





171. Install the rear planetary sun gear No.2 thrust bearing to the rear planetary sun gear.





172. Install the direct clutch hub.





173. Install the thrust bearing race No.3 thrust roller bearing and the hub thrust bearing race to the direct clutch hub.





174. Install the 2 discs (1), 2 plates (3) and the flange (2) in the order shown into the transaxle case.





175. Install the intermediate shaft assembly in the transaxle case.





176. Place a straight edge on the transaxle case and measure the distance between the 2nd coast and O/D brake flange.
177. Using vernier calipers, measure dimension (a).





178. Place a straight edge on the O/D brake piston, then measure distance (b) between the transaxle rear cove and the straight edge, using vernier calipers.
179. Calculate the piston stroke by subtracting distance (b) from distance (a) which will equal one of the following flange thicknesses: 4.0 mm (0.1575 inch), 4.2 mm (0.1654 inch), 4.4 mm (0.1732 inch), 4.6 mm (0.1811 inch).
180. Using feeler gages, measure the pack clearance. The clearance should be 2.091 - 2.491 mm (0.0823 - 0.0981 inch). If the clearance is not as specified, install a different thickness flange.





181. Install the rear clutch drum thrust roller bearing to the intermediate shaft.





182. Install the transaxle rear cover and 11 retaining bolts, to inspect the intermediate shaft assembly.

Tighten the 11 bolts to 24.5 Nm (18 ft. lbs.).





183. Using a dial indicator, measure the endplay of the intermediate shaft. The endplay should be between 0.204 - 0.966 mm (0.008 - 0.038 inch).
184. Remove the 11 bolts and transaxle rear cover.





185. Install the 4 new gaskets in the transaxle case.





186. Apply RTV Silicone Sealant GM P/N 12346240 (Canadian P/N 10953493), or the equivalent, to the transaxle rear cover.





187. Install the transaxle rear cover and 11 retaining bolts.

Tighten the 11 bolts to 24.5 Nm (18 ft. lbs.).





188. Install the forward clutch hub sub-assembly into the transaxle case.





189. Install the forward clutch hub thrust roller bearing to the forward clutch hub.





190. Install the stator shaft thrust roller bearing to the input shaft assembly.





191. Install the input shaft assembly in the transaxle case.





192. Install 2 new overdrive brake gaskets in the transaxle case.





193. Install the differential gear assembly in the transaxle case.





194. Install the oil pump and the 7 retaining bolts.

Tighten the bolts to 22 Nm (16 ft. lbs.).





195. Ensure that the input shaft turns smoothly.
196. Using a dial indicator, measure the endplay in the axial direction. Endplay should be 0.37 - 1.29 mm (0.0146 - 0.0508 inch). If the endplay is not as specified, replace the thrust roller bearing.
197. Install the front drive pinion front tapered roller bearing in the transaxle housing.





198. Using a press, install the cylindrical roller bearing into the transaxle case.





199. Install the differential gear lube apply tube.





200. Install the bearing lock plate and bolt in the transaxle case.

Tighten the bolt to 11 Nm (8 ft. lbs.).