Part 3

Transmission Overhaul Procedure Continued

164. Using a TORX� bit, install the screws.
^ Tighten the screws to 10 Nm (7 ft. lbs.).





165. Install the cam guide sleeve in the transaxle case.





166. Install the spring guide sleeve with the protruding portion facing up.





167. Place the pawl stopper plate on the protruding portion of the lock sleeve in the transaxle case.





168. Install the spring guide sleeve and torsion spring with the 2 bolts.
^ Tighten the bolts to 13 Nm (9 ft. lbs.).





169. Install the parking lock pawl in the transaxle case.





170. Install the parking lock pawl shaft with the clamp groove (1) upward, then install the pawl shaft clamp and the 2 bolts.
^ Tighten the bolts to 5.5 Nm (49 inch lbs.).





171. Coat the new O-rings with T-IV automatic transmission fluid.
172. Install the O-rings on the underdrive brake piston.





173. Place the underdrive brake piston into the case with the cup side up, being careful not to damage the O-rings.





174. Install the underdrive brake return spring sub-assembly in the transaxle case.





175. Important: Install the flange with the flat side facing downward.

Install the Plates, underdrive clutch Discs and Flange in the following order: P - D - P - D - P - D - F.





176. Using a press, compress the flange and install the underdrive clutch flange snap ring in the transaxle case.





177. Important: While applying compressed air, measure the pack clearance. The pack clearance should be within 1.15 - 1.97 mm (0.0453 - 0.0776 inch). If the pack clearance is not as specified, check for incorrect assembly.

Using a dial indicator, measure the underdrive brake pack clearance.





178. Coat the 2 new overdrive clutch drum oil seal rings with T-IV automatic transmission fluid.
179. Install the seal rings in the transaxle case.





180. Install the underdrive 1 way clutch assembly and the underdrive clutch drum thrust washer in the transaxle case.





181. Push the underdrive 1 way clutch retainer in until it clicks into place.
182. Coat the underdrive clutch drum thrust washer with petroleum jelly, then install the thrust washer on the underdrive 1 way clutch assembly.
183. Align the flukes of the discs in the underdrive brake.
184. Install the underdrive clutch drum assembly in the transaxle case.





185. Turn the underdrive clutch assembly. The clutch assembly should turn freely counterclockwise (1) and should lock clockwise (2).





186. Install the assembled bearing and race with the thrust needle roller bearing facing upward





187. Using Vernier Calipers, check the height from the sleeve to the inner race. The correct installation height should be 17.3 - 18.2 mm (0.681 - 0.717 inch).





188. Install a dial indicator on the underdrive clutch piston.





189. Important: If the piston stroke is not within 1.5 - 1.9 mm (0.059 - 0.075 inch). Install a different size flange. There are 4 thicknesses available, 2.04 mm (0.803), 2.20 mm (0.866), 2.40 mm (0.945), 2.50 mm (0.984).

While applying and releasing compressed air at a pressure of 392 - 785 kPa (57 - 114 psi) measure the underdrive clutch piston stroke.





190. Remove the underdrive planetary sun gear from the countershaft assembly.
191. Remove the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race.





192. Install the underdrive planetary sun gear sub - assembly in the transaxle case.
193. Coat the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race with petroleum jelly or equivalent.
194. Install the bearing and race in the transaxle case.
195. Align the flukes of the discs in the underdrive clutch.
196. Install the needle roller bearing with the bearings facing upward.





197. Install the countershaft assembly in the transaxle case.





198. Using Vernier Calipers, measure the distance between the tip of the countershaft and the bolt seat of the clutch support. The installation height should be 33.3 - 35.5 mm (1.311 - 1.398 inch).
199. Install the new counterdrive gear bearing on the counterdrive gear.
200. Install a new snap ring to retain the bearing.





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.).





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

Using a torque wrench, measure the starting torque of the counter drive gear.
0.11 - 0.70 Nm (0.9 - 6.1 inch lbs.).
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.





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

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





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

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.





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

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.

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

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.