201-265

Transmission Overhaul Procedure Continued





201. Using a press, install the counter drive gear.





202. Install the intermediate shaft sub-assembly in the transaxle case.





203. While holding the counter drive gear, install a new counter drive gear nut.

Tighten the nut to 180 Nm (133 ft. lbs.).





Important: If the torque exceeds the limit, replace the spacer.

204. Using a torque wrench, measure the starting torque of the counter drive gear.

Starting Torque: 0.11 - 0.70 Nm (0.9 - 6.1 inch lbs.).
Rotating Torque: 0.04 - 0.30 Nm (0.3 - 2.6 inch lbs.).





205. Using a pin punch and hammer, stake the counter drive gear nut.





206. Install the needle roller bearing in the transaxle case.





207. Using a press, install the counter driven gear on the transaxle case.
208. Install a new counter driven gear nut.

Tighten the nut to 180 Nm (133 ft. lbs.).





209. Using a dial indicator, measure the endplay of the countershaft.
Endplay should be within 0.2 - 0.9 mm (0.008 - 0.035 inch).





210. Using a pin punch and hammer, stake the counter driven gear nut.





211. Clean the mating surfaces of the transaxle case and the case cover.
212. Apply RTV Silicone Sealant GM P/N 12346240 (Canadian P/N 10953493) or the equivalent to the transaxle case cover.





213. Install bolts A: 25 mm (0.98 inch) in length into the positions shown.
214. Install bolts B: 32 mm (1.26 inch) in length into the positions shown.

Tighten all 13 bolts to 10 Nm (7 ft. lbs.).





215. Ensure that the intermediate shaft sub-assembly turns smoothly.





216. Coat the 2 new 1st and reverse O-rings with T-IV automatic transmission fluid.
217. Install the new O-rings on the 1st and reverse brake piston.





218. Install the 1st and reverse brake piston into the bore of the case, facing the spring seats upward.





219. Install the 1st and reverse brake return spring and snap ring into position.





220. Using a press, compress the 1st and reverse brake return spring sub-assembly.
221. Using snap ring pliers, install the snap ring.





222. Install the 1st and reverse brake clutch discs, in the following order: P - D - P - D - P - D - P - D -P - D - P - D.





223. Install the outer flange with the flat side facing downward.





Important: Ensure that the snap ring end gap is not aligned with one of the cutouts.

224. Using a screwdriver, install the snap ring to the transaxle case.





Important: If the clearance is not within specification, parts have been misaligned and should be rechecked for correct installation.

225. Using a feeler gage, measure the 1st and reverse brake pack clearance. Pack clearance should be 1.19 - 2.25 mm (0.0469 - 0.0886 inch).





226. Coat the needle roller bearing with petroleum jelly, then install the bearing on the ring gear.





Important: Ensure that the different lug shapes match the corresponding openings on the gear.

227. Coat the planetary gear thrust washer No. 2 with petroleum jelly, then install the thrust washer on the rear planetary gear assembly.





228. Align the splines of the rear planetary gear assembly with the flukes of the discs, then install the rear planetary gear assembly into the 1st and reverse brake discs.





229. Check that (1) of the rear planetary gear assembly is below the upper surface of the flange.





230. Place the 1 way clutch No. 2 in the transaxle case with the shiny side facing upward.
231. Install the 1 way clutch onto the inner race while turning the rear planetary gear assembly clockwise (2).
232. Check that the rear planetary gear assembly turns freely clockwise (2) and locks when turned counterclockwise (1).





233. Coat the planetary gear thrust washer No.2 with petroleum jelly, then install it on the planetary gear.





234. Ensure the end gap of the snap ring is not aligned with the cut outs.





235. Install the 2nd brake clutch flange with the flat side facing upward.





236. Install the 2nd brake clutch discs and plates, in the following order: D - P - D - P - D - P.





237. Install each of the 2nd brake piston return spring sub-assembly over the protrusions in the transaxle case.





238. Install the 2nd coast brake band guide plate retainer and brake band plate retainer so that its tip touches the transaxle case.
239. Install the retaining bolt.

Tighten the bolt to 5.5 Nm (49 inch lbs.).





240. Align the groove of the drum with the bolt and place the 2nd brake piston assembly into the transaxle case.





241. Place both ends of the snap ring in the groove, then set the snap ring in the transaxle case.

Important: Ensure the end gap of the snap ring is not aligned with one of the cut outs.

242. While compressing the piston return springs over the drum with hammer handles, install the snap ring.





243. Using compressed air, check that the 2nd brake piston moves smoothly.





244. Using a screwdriver, align the flukes of the discs in the 2nd brake.





245. Align the spline of the 1 way clutch with the flukes of the discs then install the 1 way clutch to the 2nd brake discs.





246. Check the clearance between the surface of the 2nd brake hub and the rear planetary gear. The clearance should be approximately 5 mm (0.20 inch).





247. Coat the planetary carrier thrust washer No. 3 with petroleum jelly, then install the thrust washer on the sun gear input drum.





248. Position the sun gear input drum into the 1 way clutch assembly, then turn the sun gear input drum clockwise to seat the assembly in the installed position.





249. Coat the thrust roller bearing and thrust bearing race with petroleum jelly, then install them on the front planetary gear assembly.





250. Install the front planetary gear assembly.





251. Coat the thrust bearing race and thrust roller bearing with petroleum jelly.
252. Install the thrust bearing race, then the thrust roller bearing on the front planetary ring gear assembly.





253. Install the front planetary ring gear in the transaxle case.





254. To ensure the front planetary ring gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with or under the shoulder of the intermediate shaft.





255. Coat the thrust roller bearing and thrust bearing race with petroleum jelly, then install the bearing and race on the tip of the ring gear flange.





256. Place the 2nd coast brake band assembly into the transaxle case.
257. Install the 2nd coast brake band pin in the transaxle case.





258. Coat the thrust roller bearing with petroleum jelly, then install the bearing on the forward clutch drum.





259. Coat the clutch drum thrust washer with petroleum jelly, then install the thrust washer on the direct clutch drum with the oil groove facing upward.





260. Using a screwdriver, align the flukes of the discs in the direct clutch.





Important: When the flukes of the discs are meshed correctly, the end of the bushing on the direct clutch will be flush with the surfaces of the forward clutch.

261. Mesh the hub with flukes of the direct clutch while turning the forward clutch drum.





262. Place the direct clutch assembly and the forward clutch assembly into the transaxle case.
263. While rotating the forward clutch assembly to mesh the front planetary ring gear and discs, install the assembly in the transaxle case.





264. Using a feeler gage, check the clearance between points (1) and (2). The clearance should be 3 mm (0.118 inch).





265. Coat the 2 new O-rings with T-IV automatic transmission fluid, then install the O-rings on the 2nd coast brake cover.