Part 3

Transmission Overhaul Procedure Continued





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.).





201. Install the transaxle housing oil separator and the 2 bolts in the transaxle case.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).





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





203. Install the transaxle housing and 14 bolts to the transaxle case.
^ Tighten the bolts (1) to 29 Nm (21 ft. lbs.).
^ Tighten the bolts (2) to 22 Nm (16 ft. lbs.).





204. Apply T-IV automatic transmission fluid to the 2 new C2 accumulator O-rings, then install the O-rings.





205. Important: Inspect the C2 accumulator piston spring. The free length is 66.90 mm (2.6339 inch). The outer diameter is 17.20 mm (0.6772 inch). If the spring is not as specified, replace the spring.

Install the spring and the C2 accumulator piston into the transaxle case.





206. Apply T-IV automatic transmission fluid to the 2 new C3 accumulator O-rings, then install the O-rings.





207. Important: Inspect the C3 accumulator piston spring which is blue in color. The free length is 80.20 mm (3.1575 inch). The outer diameter is 18.70 mm (0.7362 inch). If the spring is not as specified, replace the spring.

Install the spring and the C3 accumulator piston into the transaxle case.





208. Apply T-IV automatic transmission fluid to the 2 new B2 accumulator O-rings, then install the O-rings.





209. Important: Inspect the B2 accumulator piston spring which is green in color. The free length is 66.90 mm (2.6339 inch). The outer diameter is 15.50 mm (0.6102 inch). If the spring is not as specified, replace the spring.

Install the spring and the B2 accumulator piston into the transaxle case.
210. Install the spring and check ball body into the transaxle case.





211. Install a new brake drum gasket into the transaxle case.





212. Install a new transaxle case gasket into the transaxle case.





213. Install a new transaxle case 2nd brake gasket into the transaxle case.





214. Coat a new transmission wire connector O-ring with T-IV automatic transmission fluid, then install the O-ring.





215. Install the transmission wiring harness into the transaxle case.





216. Install the wiring harness retaining bolt.
^ Tighten the bolt to 5.5 Nm (48 inch lbs.).





217. Install the valve body in the transaxle case.
218. Install the valve body bolts.
^ Bolt (a) length is 32 mm (1.26 inch)
^ Bolt (b) length is 22 mm (0.87 inch)
^ Bolt (c) length is 55 mm (2.17 inch)
^ Bolt (d) length is 45 mm (1.77 inch)

Tighten the 13 bolts to 11 Nm (8 ft. lbs.).





219. Install the detent spring, spring cover.
220. Install the detent spring bolts.
^ Bolt (a) length is 14 mm (0.55 inch)
^ Bolt (b) length is 45 mm (1.77 inch)

Tighten the 2 bolts to 11 Nm (8 ft. lbs.).





221. Connect the 5 solenoid connectors.
222. Coat the new ATF temperature sensor O-ring with T-IV automatic transmission fluid, then install the O-ring.
223. Install the ATF sensor, lock plate and bolt.
^ Tighten the bolt to 11 Nm (8 ft. lbs.).





224. Coat a new valve body oil filter O-ring with T-IV automatic transmission fluid, then install the O-ring.





225. Install the valve body oil filter and 3 bolts.
^ Tighten the bolts to 11 Nm (8 ft. lbs.).
226. Install a new oil pan gasket on the oil pan.





227. Install the 2 magnets in the oil pan.





228. Install the oil pan on the transaxle case.
229. Install the 19 bolts.
^ Tighten the bolts to 8 Nm (70 inch lbs.).





230. Coat the 4 O-rings for the transaxle case plugs with T-IV automatic transmission fluid, then install the O-rings to the case plugs.
231. Install the case plugs into the transaxle case.
^ Tighten the plugs to 7.4 Nm (65 inch lbs.).





232. Coat the O-ring for the oil cooler pipe inlet union with T-IV automatic transmission fluid, then install the O-ring to the union.
233. Install the oil cooler pipe inlet union.
^ Tighten the union to 27 Nm (20 ft. lbs.).





234. Coat the O-ring for the oil cooler pipe outlet union with T-IV automatic transmission fluid, then install the O-ring to the union.
235. Install the oil cooler pipe outlet union.
^ Tighten the union to 27 Nm (20 ft. lbs.).
236. Install the breather hose.





237. Install the input turbine sensor and bolt in the transaxle case.
^ Tighten the bolt to 5.4 Nm (48 inch lbs.).





238. Install the PNP switch on the manual valve lever shaft, then temporarily install the 2 adjusting bolts.
239. Install a new lock washer and nut.
^ Tighten the nut to 6.9 Nm (61 inch lbs.).
240. Temporarily install the control lever.





241. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
242. Remove the control lever.





243. Align the groove with the neutral base line.
244. Tighten the 2 PNP switch bolts.
^ Tighten the bolts to 5.4 Nm (48 inch lbs.).





245. Using a screwdriver, stake the nut with the lock washer.





246. Install the control lever, washer and nut.
^ Tighten the nut to 13 Nm (10 ft. lbs.).

247. Install the speedometer drive hole cover and bolt on the transaxle case.
^ Tighten the bolt to 7 Nm (62 inch lbs.).