Transmission Clearance Specifications

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.

Application	Specification
Application	Metric	English
Front Differential Assembly (13)
Unloaded Rotating Torque - Old Bearing	0.70-1.20 N.m	6-11 lb in
Unloaded Rotating Torque - New Bearing	6.90-11.80 N.m	61-104 lb in
Direct Clutch (562)
Piston Bore Stroke	1.49-1.91 mm	0.059-0.075 in
Relaxed Clutch Pack Stack Up Clearance	0.67-1.24 mm	0.030-0.049 in
Available Selective Flange Thickness	3.6 mm	0.142 in
	3.8 mm	0.150 in
	4.0 mm	0.157 in
Fluid Pump Assembly (2)
Driven Gear (204) to Body Clearance	0.075-0.20 mm	0.002-0.007 in
Drive Gear (205) Tip to Body Clearance	0.013-0.342 mm	0.0005-0.014 in
Driven Gear (204) Tip to Body Clearance	0.004-0.298 mm	0.0001-0.018 in
Fluid Pump, Body Bushing, ID	38.113-38.188 mm	1.500-1.503 in
Side Clearance of Drive and Driven Gear to Body	0.03-0.10 mm	0.0012-0.004 in
Stator Shaft Bushing, ID	22.201-22.257 mm	0.874-0.876 in
Fluid Pump Body Seal Assembly (200)
Seal to Pump Body Installed Height	Flush
2nd Coast Clutch and 2nd Clutch Hub and 2nd Clutch Sprag Assembly (11) to Fluid Pump
Installed Height	51.09-51.71 mm	2.011-2.036 in
Forward and Direct Clutch Assembly (23)
Installed End Play	0.320-0.836 mm	0.013-0.033 in
Available Selective Washer (568) Thickness	0.81 mm	0.032 in
Available Selective Washer (568) Thickness	1.15 mm	0.045 in
Forward and Direct Clutch Assembly (23) to Transmission Case (17)
Installed Height	50.850-51.825 mm	2.002-2.040 in
Forward Clutch (565)
Piston Bore Stroke	0.74-1.06 mm	0.029-0.042 in
Relaxed Clutch Pack Stack Up Clearance	0.74-1.06 mm	0.029-0.042 in
Available Selective Flange Thickness	3.6 mm	0.142 in
	3.8 mm	0.150 in
	4.0 mm	0.157 in
Front Carrier Sun Gear Assembly (24)
Front Carrier, Gear Bushing, ID	30.00-30.076 mm	1.181-1.184 in
Front Carrier, Front Sun Gear Bushing, ID	22.200-22.276 mm	0.874-0.877 in
Front Carrier, Rear Sun Gear Bushing, ID	22.200-22.276 mm	0.874-0.877 in
Low and Reverse Clutch (27)
Piston Bore Stroke	1.09-1.91 mm	0.043 in
Relaxed Clutch Pack Stack Up Clearance	0.43-1.43 mm	0.017-0.056 in
1-2 Reverse Clutch (603)
Piston Bore Stroke	2.34-2.70 mm	0.092-0.106 in
Relaxed Clutch Pack Stack Up Clearance	0.84-1.63 mm	0.033-0.064 in
Available Selective Flange (621) Thickness	5.0 mm	0.197 in
	5.1 mm	0.201 in
	5.2 mm	0.205 in
	5.3 mm	0.209 in
	5.5 mm	0.216 in
Second Clutch (210)
Piston Bore Stroke	1.10-1.50 mm	0.043-0.059 in
Relaxed Clutch Pack Stack Up Clearance	0.44-1.04 mm	0.173-0.040 in
Available Selective Flange (219) Thickness	3.6 mm	0.142 in
	3.8 mm	0.150 in
	4.0 mm	0.157 in
Second Coast Clutch (222)
Piston Bore Stroke	1.24-1.96 mm	0.049-0.077 in
Relaxed Clutch Pack Stack Up Clearance	0.53-1.59 mm	0.021-0.063 in
Transmission Housing - Torque Converter Distance
Torque Converter mounting lug/pad minimum installed distance to Transmission Housing outer edge	12.5 mm	0.492 in
3rd Gear Band Servo (57) Return Springs
Outer Spring - yellow
Free/Relaxed Length	41.2 mm	1.622 in
Outer Diameter	17.9 mm	0.705 in
Inner Spring - yellow
Free/Relaxed Length	13.5 mm	0.531 in
Outer Diameter	12.6 mm	0.496 in
3rd Gear Band Servo (57)
Piston Bore Stroke	5.76-6.76 mm	0.227-0.266 in
Rod Length - 0 Grooves	76.2 mm	2.999 in
Rod Length - 1 Grooves	76.7 mm	3.020 in
Rod Length - 2 Grooves	77.2 mm	3.039 in
Rod Length - 3 Grooves	77.7 mm	3.059 in
Rod Length - 4 Grooves	78.2 mm	3.079 in
4-5 Clutch Backing Plate (567)
Available Selective 4-5 Clutch Backing Plates	3.6 mm	.142 in
	3.8 mm	.150 in
	4.0 mm	.158 in
4-5 Clutch (582)
4-5 Clutch Housing Bushing, ID	36.125-36.200 mm	1.422-1.425 in
4-5 Clutch Piston Stroke	1.52-1.90 mm	0.0598-0.0748 in