Case and Final Assembly

1. Install the rear ball bearing snap rings in the case.
2. Expand the snap rings with snap ring pliers and slide rear ball bearings into bearing bores. Snap ring grooves on bearings should be up on output shaft and down on input shaft.
3. Install O-ring onto one end of reverse idler shaft.
4. Lube and install reverse idler gear bearing.
5. Install O-ring on opposite end of shaft.
6. Install reverse idler gear into case.

IMPORTANT: Chamfer side of gear goes towards rear of case.

7. Lube O-ring and install shaft through gear into case. Use a twisting motion and make sure O-ring stays in position. The end of the shaft with the flat should be up.

IMPORTANT: Apply petroleum jelly on case and O-rings and install shaft using a twisting motion.

8. Install reverse idler shaft cap using a twisting motion and torque the two bolts.

IMPORTANT: Clean and lubricate fasteners with Transaxle Fluid. Wipe off excess fluid and install.

- Torque: 20 N.m (15 ft. lbs.).
9. Install case to rear cover dowel pins if necessary.

NOTICE: A bolt may be used to pull the pins into position.





10. If a new case is being installed or if the filter bypass valve was removed for any reason install a new valve into case using a socket with the same outer diameter as the bypass valve.





11. Install transaxle filter tube if removed or if new case is being installed.
- Torque: 31 N.m (23 ft. lbs.).





12. Install manual detent shaft oil seal using a bolt, nut and washers that will not damage the bore.
13. Install case to converter housing gasket.





IMPORTANT: Clean case and housing surfaces, use sealant Loctite(R) 515 (Saturn PA 21005993) or equivalent. Apply onto both sides of gasket or case halves using a small roller.

14. Check to make sure the oil pump O-ring, reverse drive gear thrust washer, reverse driven gear thrust washer and park lever rod are in position before installing the case.





15. Install the transaxle case, lower case over the shafts and work down onto the differential bearing. It may be necessary to turn the reverse idler gear so case can fit all the way down on the converter housing.





16. Install the case to converter housing bolts using torque sequence:

IMPORTANT: Clean and lubricate fasteners with Transaxle Fluid. Wipe off excess fluid and install.

Short Bolt
- Torque: 25 N.m (18 ft. lbs.).
Long Bolt
- Torque: 28 N.m (21 ft. lbs.).

IMPORTANT: Two bolts are on the torque converter side of the housing. Do not turn transaxle over until 1st gears are installed.

17. Check to make sure both shafts rotate freely.





18. Measure differential end play by using differential end play tool SA9112T. Select the largest gauge tool that will fit between the case bearing pocket and the outer differential race.





19. Use the part number on the tool to choose and install the correct snap ring.





IMPORTANT: Prior to using seal installer SA9113T inspect the tool for any nicks or burrs that could damage the seal lip.

20. Apply Loctite(R) 515 Gasket Eliminator sealant (Saturn P/N 21005993) or equivalent to area of axle seal that mates to case and install the case side axle seal using tool SA9113T.
21. Install retaining ring.





22. Install forward/reverse servo piston seal ring if necessary.

IMPORTANT: Prior to using servo piston seal installer SA9143T inspect the tool for any nicks or burrs that could damage the servo piston seal.

a. Place servo piston on seal installer support base SA9137T-2.
b. Install expander cone SA9137T-1 to servo piston.
c. Lube seal ring and position on expander cone.
d. Use seal pusher SA9143T to install seal ring.

IMPORTANT: Lube seal ring with Transaxle Fluid before installation.





e. Place servo piston on seal sizer support base SA9137T-4.
f. Size seal rings by placing sizer SA9137T-3 over piston, with large internal diameter down, until it bottoms out on work table.
23. Slide the FWD/reverse fork onto the second reverse sleeve.

IMPORTANT: When installing servo piston, lube seal and use care not to roll or cut seal while inserting into bore. If servo piston is being replaced, be sure current part is used.





24. Insert the FWD/reverse servo piston into the bore and line up fork and servo shaft as servo is pushed in. Before pushing the servo all the way in, align counter bore bolt hole in servo with hole in fork. The flat on the servo shaft should face the valve body opening in the case.
25. Clean bolt threads and apply Loctite(R) 242 Threadlocker (Saturn P/N 21485277) or equivalent on bolt threads.
26. Install fork to servo piston bolt and torque.

- Torque: 10 N.m (89 inch lbs).

27. Install servo spring.
28. Install servo cover O-ring to cover and install cover. Torque two bolts.

IMPORTANT: Clean and lubricate fasteners with Transaxle Fluid. Wipe off excess fluid and install.

- Torque: 20 N.m (15 ft. lbs.).





29. Install 1st driven gear and spray assembly.
30. Install 1st driven gear thrust washer.
31. Move park pawl actuator rod to engage parking pawl.
32. Hand start the output shaft clamp nut. Run down with a torque wrench.

NOTICE: Use new nut due to insufficient torque retention of old nut. Clean shaft threads with wire brush. When tightening and torquing this nut it must be done quickly. The thread locking material used on the new nut will cure in a short time and an incorrect torque will occur.

- Torque: 150 N.m (111 ft. lbs.).





33. Lay 1st clutch housing on flat surface.

NOTICE: Make sure tabs on 1st gear thrust washer line up with slots on the 1st clutch housing assembly hub or damage to the 1st gear thrust washer will occur.

34. Apply a generous amount of petroleum jelly to hold the 1st gear thrust washer in place and install the 1st gear thrust washer on the 1st clutch housing assembly hub.

IMPORTANT: Chamfer side goes toward the clutch housing and flat side goes toward 1st gear.

35. Install thrust bearing with rollers (down) toward 1st gear thrust washer.
36. Install 1st clutch, clutch (needle) bearing.
37. Install 1st drive gear and hub assembly into 1st clutch housing assembly by twisting the gear to align the gear hub with the clutch tangs.
38. When installing the 1st drive gear and hub assembly into the clutch pack, rotate the gear and hub assembly back and forth to align the clutch plates. If you are not sure that all of the clutch plates have been engaged, lift the gear out of the clutch housing and verify that all clutch tangs are aligned.
39. Install 1st gear thrust washer.





40. Hold the 1st gear and clutch assembly together and install on the input shaft.

IMPORTANT: If assembly is not held together, the gear hub may slide out of the clutch housing which may allow the 1st gear thrust washer to move out of location or allow clutch plates to be pinched when the input shaft nut is torqued.

41. Install 1st gear and hub assembly, and 1st clutch housing assembly on the input shaft.





42. Install the input shaft holding tool SA9119T.

NOTICE: Use new nut due to insufficient torque retention of old nut. Clean shaft threads with wire brush. When tightening and torquing this nut it must be done quickly. The thread locking material used OR the new nut will cure in a short time and an incorrect torque will occur.

43. Hand start the input shaft clamp nut. Run the nut down with a torque wrench.
- Torque: 150 N.m (111 ft. lbs.).

IMPORTANT: To verify 1st clutch assembly, gear and hub are positioned properly, check clearance between 1st drive gear and bearing.

Clearance:
- Standard: 0.075mm - 0.425 mm (0.003 in. - 0.017 in.).

After the input and output shaft nut have been installed, verify proper operation.

a. Engage park pawl.
b. Rotate the input shaft by turning the 1st clutch housing. The clutch housing should turn freely in both directions.
- If input shaft turns freely in one direction only, the 1st clutch is binding.
- If input shaft will not turn freely in either direction, 2nd, 3rd, or 4th clutch is binding.





44. Connect the manual valve link to the manual detent lever.
45. Insert the manual detent and link into the transaxle, and connect the park lever actuator rod to the detent lever.
46. Hold the detent lever in position and slide the manual detent lever shaft through the case and detent lever.
47. Line up the flats on the manual detent lever with the flats on the manual detent shaft and install the attachment nut.
- Torque: 12 N.m (106 inch lbs).





48. Install the park/neutral position switch and retaining bolts; do not tighten at this point.





49. Install new end cover gasket onto clean surface of case.
50. Install the end cover to the transaxle case. Insert the input and output shaft tubes into the ends of the shafts and lower cover. If the cover does not seat, turn the input and output shafts to help align the tubes with the bushings in the shafts.

IMPORTANT: Do not use force as tube can bend easily. Rotate the shafts to align the tubes.





51. Install the end cover to case bolts and torque using torque sequence.

IMPORTANT: Clean and lubricate fasteners with Transaxle Fluid. Wipe off excess fluid and install.

- Torque: 28 N.m (21 ft. lbs.).





52. To verify proper assembly, aircheck clutches and servo before installing valve body.
53. Turn the transaxle, valve body side up.

NOTICE: Prior to using seal installer SA9113T inspect the tool for any nicks or burrs that may damage the seal lip.

54. Apply Loctite(R) 515 is Gasket Eliminator sealant P/N 21005993 or equivalent to area of seal that mates to housing and install the converter housing axle seal using axle seal installer SA9113T.
55. Install two converter housing to case bolts.

IMPORTANT: Clean and lubricate fasteners with Transaxle Fluid. Wipe off excess fluid and install.

- Torque: 25 N.m (18 ft. lbs.).





56. Install drain plug.
- Torque: 30 N.m (22 ft. lbs.).








57. Install manual valve link in manual valve and install the valve body assembly. The valve body has two dowel bolts that assist in aligning valve body to case.
58. Lower valve body and insert manual link into manual valve.





59. Torque valve body-to-case bolts.
- Torque: 11 N.m (97 inch lbs).

IMPORTANT: Clean and lubricate fasteners with Transaxle Fluid. Wipe off excess fluid and install.





60. Adjust park/neutral position switch.

IMPORTANT: While adjusting the park neutral position switch, always rotate the switch towards the engine to achieve continuity. A diagnostic trouble code P0706 could result if this procedure is not followed.

a. Place transaxle in D (Drive). Use ohmmeter or continuity tester to check for continuity across terminals on selector switch. Rotate the park neutral position switch from the left fender towards the engine until continuity is achieved.
b. Tighten switch-to-case bolts. After switch-to-case bolts have been tightened, recheck continuity.
- Torque: 14 N.m (124 inch lbs).

IMPORTANT: Digital Volt/Ohm meter (DVM) with audible continuity test is preferred. Do not stick probe in PNP switch terminal hole; use male terminals on PNP switch or faulty readings could occur.





61. Clean transaxle case and valve body cover sealing surfaces with Saturn Choke and Brake Cleaner or equivalent, applied with a clean shop towel

IMPORTANT: Install new gasket during assembly.

62. Align the valve body cover gasket on the valve body cover and install on the transaxle case.
63. When installing the valve body cover, make sure to properly torque the valve body cover bolts using the torque sequence shown.
- Torque: 12 N.m (106 inch lbs).

IMPORTANT: Clean and lubricate fasteners with Transaxle Fluid. Wipe off excess fluid and install.

64. Verify torque of the valve body cover bolts to account for gasket relaxation using the torque sequence shown.
- Torque: 12 N.m (106 inch lbs).





65. Install input shaft to converter O-ring on input shaft (if new O-ring has not already been installed during input shaft assembly). Make sure O-ring is between back-up ring and converter case and not next to input shaft splines.





66. If removed, install back-up ring using SA9135T expander and installer.





67. Check converter end play using SA9163T.
a. Install tool down into converter and tighten so that the end of the tool will hold onto the splines inside converter
b. Set up dial indicator to end of tool
- End Play:
Standard: 0.00 mm-0.60 mm (0.000 in. - 0.026 in.).





68. Install O-ring to converter and install torque converter. Rotate and support converter to align input shaft spline and pump drive slots to converter.
69. Rotate converter so that paint dot is down.





70. Place clean magnet onto new filter.
71. Using Transaxle Fluid lube filter seal. Install transaxle pressure filter. Spin filter until gasket makes contact and tighten one additional turn.
72. Install transaxle temperature sensor and torque. When installing sensor, use Saturn sealant with Teflon (Saturn P/N 21485278) or equivalent on threads.
- Torque: 8 N.m (71 inch lbs).





73. Install cooler line fittings if removed.
- Torque: 29 N.m (18 ft. lbs.).





74. Install turbine speed sensor and torque.

IMPORTANT: Clean and lubricate turbine speed sensor with Transaxle Fluid. Wipe off excess fluid and install.

- Torque: 26 N.m (19 ft. lbs.).
75. Install vehicle speed sensor and torque.
- Torque: 26 N.m (19 ft. lbs.).





76. Install transaxle fluid fill tube. Torque retaining bolt.

IMPORTANT: Clean and lubricate fasteners with Transaxle Fluid. Wipe off excess fluid and install.

- Torque: 12 N.m (106 inch lbs).
77. After rebuilding a transaxle the TCM adaptives should be reset using the service stall system or Scan tool. Follow the learn-in procedure under Powertrain Management.