Part 4

Transmission Overhaul Procedure Continued





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.





261. 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.

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.





266. Install the spring 2nd coast brake piston assembly and 2nd coast brake cover into the transaxle case.





267. Using snap ring pliers, install the 2nd coast brake piston snap ring





268. Inspect the piston stroke of the 2nd coast brake by applying a small amount of paint to the piston rod where it meets the case.





269. Important: If the piston stroke exceeds 1.5 - 3.0 mm (0.059 - 0.118 inch). Install a new piston rod.

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





270. Using a soft faced hammer, install the governor pressure tube in the transaxle case.





271. Install the transaxle apply tube clamp and bolt in the transaxle case.
^ Tighten the bolt to 5.5 Nm (49 inch lbs.).





272. Coat a new O-ring with T-IV automatic transmission fluid, then install the O-ring on the oil pump.
273. Place the oil pump over the input shaft, then align the bolt holes of the pump body with holes in the transaxle case.





274. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the input shaft through the direct clutch drum.





275. Install the 6 bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





276. Important: If the end play is not within 0.3 - 0.9 mm (0.012 - 0.035 inch). Replace the race for the end of the input shaft assembly. There are 3 thicknesses available, 0.8 mm (0.31 inch), 1.40 mm (0.055 inch), 1.0 mm (0.039 inch).

Using a dial indicator, measure the end play of the input shaft.





277. Ensure that the input shaft rotates smoothly.





278. Install the governor apply gasket No. 2 in the transaxle case.
279. Install the transaxle case plate No.1 and bolt in the transaxle case.
^ Tighten the bolt to 10 Nm (7 ft. lbs.).





280. Install the differential assembly into the transaxle case.





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





283. Apply Threadlocker 242 GM P/N 12345382 or the equivalent to the threads of bolts (2). These bolts are 35 mm (1.38 inch) in length.
284. Install the (2) bolts.
^ Tighten the bolts to 28 Nm (20 ft. lbs.).
285. Install the (1) bolts.
^ Tighten the bolts to 28 Nm (20 ft. lbs.).





286. Using J 35405 and a torque wrench, rotate the differential in both directions to seat the bearing.
287. Using J 35405 and a torque wrench, measure the preload of the side bearing.
^ New Bearing: 0.8 - 1.4 Nm (6.9 - 12.2 inch lbs.).
^ Used Bearing: 0.04 - 0.7 Nm (3.5 - 6.1 inch lbs.).

288. Important: The preload will change about 0.3 - 0.4 Nm (2.6 - 2.9 inch lbs.) according to a change in shim thickness of 0.05 mm (0.0020 inch).

If the preload is not within specification, remove the differential from the transaxle case. Select a new transaxle case side adjusting shim.





289. Using a 14 mm (0.55 inch) socket and hammer, drive in a new manual valve lever shaft oil seal.
290. Apply multi-purpose grease to the seal lip.





291. Install the parking lock rod assembly to the manual valve lever sub-assembly.
292. Slide in the manual valve lever shaft, then install the washer plate, a new spacer and manual valve lever sub-assembly.





293. Important: Ensure there is a washer between the retaining spring and case.

Install the retainer spring.





294. Using a pin punch and hammer, install the roll pin.
295. Position the spacer, then stake the spacer.





296. Coat the new O-rings with T-IV automatic transmission, them install the O-rings on the accumulator pistons.

297. Important: Springs should be installed in the following order: A - Yellow, B - Yellow, C - Light Blue, D - Purple, E - Pink.

Install the accumulator springs and pistons in the transaxle case.





298. Install a new brake drum gasket until it makes contact with the 2nd brake drum.





299. Install the new governor apply gasket No.1 in the transaxle case.





300. Install the check ball body and spring in the transaxle case.





301. Coat a new O-ring with T-IV automatic transmission fluid, then install the O-ring on the transmission wire harness connector.
302. Install the transmission wire into the transaxle case.





303. Install the connector retaining bolt.
^ Tighten the bolt to 5.5 Nm (49 inch lbs.).





304. Connect the manual valve connecting rod to the manual valve lever.





305. Important: The bolt length for: Locations (1) - 20 mm (0.79 inch), Locations (2) - 28 mm (1.18 inch), Locations (3) - 50 mm (1.97 inch).

Install the valve body with the 17 retaining bolts.





306. Connect the solenoid connectors.





307. Install the manual detent spring sub-assembly.
308. Install the manual detent spring cover and bolt.
^ Tighten the bolt to 10 Nm (7 ft. lbs.).





309. Important: The bolt length for: Locations (1) - 12 mm (0.47 inch), Location (2) - 20 mm (0.79 inch).

Install the valve body oil filter and gasket, then install the 3 bolts
^ Tighten the bolts to 10 Nm (7 ft. lbs.).





310. Install the 2 transaxle oil pan magnets on the oil pan.





311. Install a new oil pan gasket and oil pan on the transaxle case.
312. Install the 18 oil pan retaining bolts.
^ Tighten the bolts to 5.3 Nm (47 inch lbs.).





313. Coat 2 new O-rings with T-IV automatic transmission fluid.
314. Install the O-rings on the 2 oil cooler pipe unions.
315. Install the unions on the transaxle case.
^ Tighten the unions to 28 Nm (20 ft. lbs.).





316. Install the PNP switch to the manual shift lever
317. Place a new lock washer and nut on the manual shift lever.
^ Tighten the nut to 7.0 Nm (62 inch lbs.).
318. Temporarily install the 2 PNP switch retaining bolts.





319. Temporarily install the transmission control shift lever.
320. Turn the lever counterclockwise until it stops, then turn the lever clockwise 2 notches.
321. Remove the lever from the transaxle case.





322. Align the groove (1) with neutral line (2).
323. Tighten the 2 bolts.
^ Tighten the bolts to 5.5 Nm (49 inch lbs.).
324. Install the transmission control shaft lever with the nut and washer.
^ Tighten the nut to 12 Nm (8 ft. lbs.).
325. Install the transaxle case plug No. 1 with a new O-ring on the transaxle case.
326. Install the breather plug No. 1 with a new O-ring on the transaxle case.
327. Install the breather hose.