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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1781 (Automatic Transmission Overhaul - 4 Speed-Mu4) >> Repair Instructions >> Transmission Overhaul Procedure >> Overhaul Procedure

Overhaul Procedure

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the breather plug, O-ring and hose from the transaxle case.
  2. Remove the breather plug.
  3. Remove the nut, washer and control shift lever from the transaxle.
  4. Pry up the lock tab on the washer, then remove the retaining nut.
  5. Remove the 2 PNP switch retaining bolts, then remove the switch from the transaxle.
    Fig 1: Removing PNP Switch & Retaining Bolts
    G01384551Courtesy of GENERAL MOTORS CORP.
  6. Remove the 2 oil cooler unions from the transaxle.
  7. Remove the O-rings from the unions.
    Fig 2: Removing Oil Cooler Unions From Transaxle
    G01384552Courtesy of GENERAL MOTORS CORP.

    Important:  Do not turn the transaxle over to remove the oil pan as it will contaminate the valve body with foreign material within the oil pan.

  8. Remove the oil pan retaining bolts, then the oil pan.
  9. Place the transaxle on wooden blocks to prevent damage to the pipes.
    Fig 3: Removing Oil Pan Retaining Bolts
    G01384553Courtesy of GENERAL MOTORS CORP.
  10. Remove the 3 oil filter retaining bolts, then the oil filter and gasket.
    Fig 4: Locating Oil Filter Retaining Bolts
    G01384554Courtesy of GENERAL MOTORS CORP.
  11. Remove the bolt, manual detent spring and spring cover.
    Fig 5: Identifying Bolt, Manual Detent Spring & Spring Cover
    G01384555Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the solenoid connectors.
    Fig 6: View Of Solenoid Connectors
    G01384556Courtesy of GENERAL MOTORS CORP.
  13. Remove the 17 valve body retaining bolts.
    Fig 7: Locating Valve Body Retaining Bolts
    G01384557Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the connecting rod from the manual valve.
  15. Remove the valve body from the transaxle case.
    Fig 8: Disconnecting Manual Valve Connecting Rod
    G01384558Courtesy of GENERAL MOTORS CORP.
  16. Remove the transaxle wiring harness retaining bolt.
    Fig 9: Identifying Transaxle Wiring Harness Retaining Bolt
    G01384559Courtesy of GENERAL MOTORS CORP.
  17. Remove the wiring harness from the transaxle case.
  18. Remove the O-ring from the harness connector.
    Fig 10: Removing Wiring Harness From Transaxle Case
    G01384560Courtesy of GENERAL MOTORS CORP.
  19. Remove the check ball body and spring from the transaxle case.
    Fig 11: Removing Check Ball Body & Spring
    G01384561Courtesy of GENERAL MOTORS CORP.
  20. Remove the governor apply gasket from the transaxle case.
    Fig 12: Removing Governor Apply Gasket
    G01384562Courtesy of GENERAL MOTORS CORP.
  21. Remove the brake drum gasket from the transaxle case.
    Fig 13: Removing Brake Drum Gasket
    G01384563Courtesy of GENERAL MOTORS CORP.
  22. Cover the B-2 accumulator piston with a shop towel.
  23. Using compressed air at low pressure 98 kPa (14 psi) push out the B-2 accumulator piston from the transaxle case.
  24. Remove the 2 O-rings from the accumulator piston.
    Fig 14: Removing B-2 Accumulator Piston Using Compressed Air
    G01384564Courtesy of GENERAL MOTORS CORP.
  25. Cover the C-2 accumulator piston with a shop towel.
  26. Using compressed air at low pressure 98 kPa (14 psi) push out the C-2 accumulator piston from the transaxle case.
  27. Remove the 2 O-rings from the accumulator piston.
    Fig 15: Removing C-2 Accumulator Piston Using Compressed Air
    G01384565Courtesy of GENERAL MOTORS CORP.
  28. Cover the C-1 accumulator piston with a shop towel.
  29. Using compressed air at low pressure 98 kPa (14 psi) push out the C-1 accumulator piston from the transaxle case.
  30. Remove the 2 O-rings from the accumulator piston.
    Fig 16: Removing C-1 Accumulator Piston Using Compressed Air
    G01384566Courtesy of GENERAL MOTORS CORP.
  31. Cover the C-3 accumulator piston with a shop towel.
  32. Using compressed air at low pressure 98 kPa (14 psi) push out the C-3 accumulator piston from the transaxle case.
  33. Remove the 2 O-rings from the accumulator piston.
    Fig 17: Removing C-3 Accumulator Piston Using Compressed Air
    G01384567Courtesy of GENERAL MOTORS CORP.
  34. Using a screwdriver and a hammer, unstake the spacer then remove the spacer from the transaxle case.
    Fig 18: Unstaking & Removing Spacer From Transaxle Case
    G01384568Courtesy of GENERAL MOTORS CORP.

    Important:  Drive out the spring pin slowly so that it does not fall into the transaxle case.

  35. Using a punch and hammer, remove the spring pin.
    Fig 19: Removing Spring Pin
    G01384569Courtesy of GENERAL MOTORS CORP.
  36. Remove the retainer spring.
    Fig 20: Removing Retainer Spring
    G01384570Courtesy of GENERAL MOTORS CORP.
  37. Slide out the manual valve lever shaft, then remove the manual valve lever assembly and washer plate.
    Fig 21: Removing Manual Valve Lever Shaft
    G01384571Courtesy of GENERAL MOTORS CORP.
  38. Using a screwdriver, remove the manual valve lever shaft oil seal.
    Fig 22: Removing Manual Valve Lever Shaft Oil Seal
    G01384572Courtesy of GENERAL MOTORS CORP.
  39. Remove the 17 transaxle case bolts.
  40. Separate the transaxle housings.
    Fig 23: View Of Transaxle Case Bolts
    G01384573Courtesy of GENERAL MOTORS CORP.
  41. Remove the differential assembly from the transaxle case.
  42. Remove the transaxle case plate bolt and transaxle case plate from the transaxle housing.
    Fig 24: Removing Differential Assembly
    G01384574Courtesy of GENERAL MOTORS CORP.
  43. Remove the governor apply gasket from the transaxle case.
    Fig 25: Removing Governor Apply Gasket
    G01384575Courtesy of GENERAL MOTORS CORP.
  44. Remove the 6 oil pump assembly retaining bolts.
    Fig 26: Locating Oil Pump Assembly Retaining Bolts
    G01384576Courtesy of GENERAL MOTORS CORP.
  45. Lift out the oil pump assembly from the transaxle case.
    Fig 27: Removing Oil Pump Assembly
    G01384577Courtesy of GENERAL MOTORS CORP.
  46. Using a screwdriver, remove the O-ring from the oil pump.
    Fig 28: Removing Oil Pump O-Ring Using Flat Bladed Tool
    G01384578Courtesy of GENERAL MOTORS CORP.
  47. Remove the bolt and the apply tube clamp from the transaxle case.
    Fig 29: Removing Apply Tube Clamp & Bolt
    G01384579Courtesy of GENERAL MOTORS CORP.
  48. Remove the governor pressure tube from the transaxle case.
    Fig 30: Removing Governor Pressure Tube
    G01384580Courtesy of GENERAL MOTORS CORP.
  49. Apply a index mark to the piston at the point where it meets the transaxle case.
    Fig 31: Applying Index Mark to Piston
    G01384581Courtesy of GENERAL MOTORS CORP.

    Important:  If the piston stroke is not within 1.5-3.0 mm (0.059-0.118 in). Inspect the brake band.

  50. While applying and releasing compressed air at a pressure of 392-785 kPa (57-114 psi) measure the piston stroke.
    Fig 32: Measuring Piston Stroke Using Compressed Air
    G01384582Courtesy of GENERAL MOTORS CORP.
  51. Remove the 2nd coast brake piston snap ring.
    Fig 33: Removing 2nd Coast Brake Piston Snap Ring
    G01384583Courtesy of GENERAL MOTORS CORP.
  52. Using compressed air at low pressure 98 kPa (14 psi) push out the cover into a shop towel.
    Fig 34: Using Compressed Air To Push Out Cover
    G01384584Courtesy of GENERAL MOTORS CORP.
  53. Remove the cover, 2nd coast brake piston assembly and spring.
  54. Remove the 2 O-rings from the coast brake cover.
    Fig 35: Removing Cover, 2nd Coast Brake Piston Assembly & Spring
    G01384585Courtesy of GENERAL MOTORS CORP.
  55. Remove the direct clutch with the forward clutch from the transaxle case.
    Fig 36: Removing Direct Clutch & Forward Clutch
    G01384586Courtesy of GENERAL MOTORS CORP.
  56. Remove the direct clutch from the forward clutch.
    Fig 37: Removing Direct Clutch From Forward Clutch
    G01384587Courtesy of GENERAL MOTORS CORP.
  57. Remove the clutch drum thrust washer and the 2 thrust needle roller bearings from the forward clutch.
    Fig 38: Removing Clutch Drum Thrust Washer & Thrust Needle Roller Bearings
    G01384588Courtesy of GENERAL MOTORS CORP.
  58. Pull out the 2nd coast brake band pin.
  59. Remove the 2nd coast brake band assembly from the transaxle case.
    Fig 39: Removing 2nd Coast Brake Band Pin
    G01384589Courtesy of GENERAL MOTORS CORP.
  60. Inspect the 2nd coast brake band assembly. If peeled, discolored, or if a part of the printed numbers (1) are defaced, replace the 2nd coast brake band assembly.
    Fig 40: View Of 2nd Coast Brake Band Assembly
    G01384590Courtesy of GENERAL MOTORS CORP.
  61. Remove the front planetary ring gear assembly from the transaxle case.
    Fig 41: Removing Front Planetary Ring Gear Assembly
    G01384591Courtesy of GENERAL MOTORS CORP.
  62. Remove the thrust bearing and thrust bearing race from the front planetary ring gear assembly.
    Fig 42: Removing Front Planetary Ring Gear Assembly Thrust Bearing & Race
    G01384592Courtesy of GENERAL MOTORS CORP.
  63. Remove the front planetary gear assembly and the thrust bearing race from the transaxle case.
    Fig 43: Removing Front Planetary Gear Assembly & Thrust Bearing Race
    G01384593Courtesy of GENERAL MOTORS CORP.
  64. Remove the thrust bearing and the thrust bearing race from the front planetary gear assembly.
    Fig 44: Removing Front Planetary Gear Assembly Thrust Bearing Race & Bearing
    G01384594Courtesy of GENERAL MOTORS CORP.
  65. Using a feeler gage, measure the planetary pinion gear thrust clearance. If clearance exceeds 0.5 mm (0.020 in), replace the front planetary gear assembly.
    Fig 45: Measuring Planetary Pinion Gear Thrust Clearance Using Feeler Gage
    G01384595Courtesy of GENERAL MOTORS CORP.
  66. Remove the planetary sun gear sub-assembly with the sun gear input drum and planetary thrust washer from the transaxle case.
    Fig 46: Removing Planetary Sun Gear Sub-Assembly
    G01384596Courtesy of GENERAL MOTORS CORP.
  67. Remove the 1 way clutch assembly from the transaxle case.
    Fig 47: Removing 1 Way Clutch Assembly
    G01384597Courtesy of GENERAL MOTORS CORP.
  68. Hold the sun gear (1) and turn the hub (4). The hub should turn freely clockwise (3) and should lock if turned counterclockwise (2).
    Fig 48: Checking Sun Gear & Hub Rotation
    G01384598Courtesy of GENERAL MOTORS CORP.
  69. Using compressed air, check that the 2nd brake piston moves smoothly.
    Fig 49: Checking 2nd Brake Piston Action Using Compressed Air
    G01384599Courtesy of GENERAL MOTORS CORP.
  70. Remove the bolt and brake band guide plate retainer and the 2nd coast brake band guide plate from the transaxle case.
    Fig 50: Removing 2nd Coast Brake Band Guide Plate & Brake Band Guide Plate Retainer
    G01384600Courtesy of GENERAL MOTORS CORP.
  71. Using a screwdriver, remove the snap ring from the transaxle case.
    Fig 51: Removing Snap Ring Using Flat Bladed Tool
    G01384601Courtesy of GENERAL MOTORS CORP.
  72. Remove the 2nd brake piston return spring assembly from the transaxle case.
    Fig 52: Removing 2nd Brake Piston Return Spring Assembly
    G01384602Courtesy of GENERAL MOTORS CORP.
  73. Remove the 2nd brake piston return spring assembly from the transaxle.
    Fig 53: Removing 2nd Brake Piston Return Spring Assembly
    G01384603Courtesy of GENERAL MOTORS CORP.
  74. Remove the plates, 2nd brake clutch disc and flange from the transaxle case.
    Fig 54: Removing 2nd Brake Clutch Disc, Flange & Plates
    G01384604Courtesy of GENERAL MOTORS CORP.
  75. Check the 2nd brake clutch discs. If the sliding surfaces of the discs, plates and flanges are worn, discolored, or if a part of the printed numbers (1) are defaced, replace all the discs and plates.
    Fig 55: Locating Printed Numbers On 2nd Brake Clutch Disc
    G01384605Courtesy of GENERAL MOTORS CORP.
  76. Using 2 screwdrivers, remove the snap ring from the transaxle case.
    Fig 56: Removing Snap Ring From Transaxle Case
    G01384606Courtesy of GENERAL MOTORS CORP.
  77. Remove the 1 way clutch assembly and the rear planetary gear assembly with the 2 planetary carrier thrust washers from the transaxle case.
    Fig 57: Removing 1 Way Clutch Assembly & Rear Planetary Gear Assembly
    G01384607Courtesy of GENERAL MOTORS CORP.
  78. Remove the 2 planetary carrier thrust washers from the rear planetary gear assembly.
    Fig 58: Removing Planetary Carrier Thrust Washers
    G01384608Courtesy of GENERAL MOTORS CORP.
  79. Remove the thrust bearing and thrust bearing race from the transaxle case.
    Fig 59: Removing Thrust Bearing & Thrust Bearing Race
    G01384609Courtesy of GENERAL MOTORS CORP.
  80. Using a feeler gage, measure the rear planetary pinion gear thrust clearance. If clearance exceeds 0.5 mm (0.020 in), replace the rear planetary gear assembly.
    Fig 60: Checking Rear Planetary Pinion Gear Thrust Clearance Using Feeler Gage
    G01384610Courtesy of GENERAL MOTORS CORP.
  81. Using a feeler gage, measure the first and reverse brake pack clearance. If clearance exceeds 2.25 mm (0.0886 in), check the disc.
    Fig 61: Measuring First & Reverse Brake Pack Clearance Using Feeler Gage
    G01384611Courtesy of GENERAL MOTORS CORP.
  82. Using a screwdriver, remove the snap ring from the transaxle case.
    Fig 62: Removing Snap Ring Using Flat Bladed Tool
    G01384612Courtesy of GENERAL MOTORS CORP.
  83. Remove the flange, plates and 1st and reverse brake clutch discs from the transaxle case.
    Fig 63: Removing 1st & Reverse Brake Clutch Discs, Plates & Flange
    G01384613Courtesy of GENERAL MOTORS CORP.
  84. Check the 1st and reverse clutch discs. If the sliding surfaces of the discs, plates and flanges are worn, discolored, or if a part of the printed numbers are defaced, replace all the discs and plates.
    Fig 64: Identifying 1st & Reverse Brake Clutch Disc Printed Number Location
    G01384614Courtesy of GENERAL MOTORS CORP.
  85. Using a press, slightly compress the return spring until the snap ring is free from the return spring.
    Fig 65: Compressing Return Spring
    G01384615Courtesy of GENERAL MOTORS CORP.
  86. Using snap ring pliers, remove the snap ring.
    Fig 66: Returning Snap Ring From Transaxle Case
    G01384616Courtesy of GENERAL MOTORS CORP.
  87. Using compressed air at low pressure 98 kPa (14 psi) push out the 1st and reverse brake piston from the transaxle case.
    Fig 67: Removing 1st & Reverse Brake Piston Using Compressed Air
    G01384617Courtesy of GENERAL MOTORS CORP.
  88. Using a screwdriver, remove the 2 O-rings from the 1st and reverse brake piston.
    Fig 68: View Of Transaxle Case
    G01384618Courtesy of GENERAL MOTORS CORP.
  89. Remove the 13 bolts from the transaxle case.
    Fig 69: Identifying Of Transaxle Case Bolts
    G01384619Courtesy of GENERAL MOTORS CORP.
  90. Using a soft faced hammer, tap the rear transaxle case cover to remove the rear case from the transaxle case.
    Fig 70: Removing Rear Transaxle Case Cover
    G01384620Courtesy of GENERAL MOTORS CORP.
  91. Using a punch and hammer, unstake the counterdrive gear nut.
    Fig 71: Unstaking Counterdrive Gear Nut
    G01384621Courtesy of GENERAL MOTORS CORP.
  92. Remove the counterdrive gear nut.
    Fig 72: Removing Counterdrive Gear Nut
    G01384622Courtesy of GENERAL MOTORS CORP.
  93. Remove the intermediate shaft sub-assembly from the transaxle case.
    Fig 73: Removing Intermediate Shaft Sub-Assembly
    G01384623Courtesy of GENERAL MOTORS CORP.
  94. Using a press, remove the counterdrive gear (1) from the transaxle case.
  95. Remove the snap ring from the counterdrive gear bearing.
  96. Remove the counterdrive gear bearing from the counterdrive gear.
    Fig 74: Removing Counterdrive Gear
    G01384624Courtesy of GENERAL MOTORS CORP.
  97. Using a punch and hammer, unstake the counterdriven gear nut.
    Fig 75: Unstaking Counterdriven Gear Nut
    G01384625Courtesy of GENERAL MOTORS CORP.
  98. While holding the counter shaft assembly (1), remove the counterdriven gear nut.
  99. Using a suitable puller, remove the counterdriven gear.
    Fig 76: Securing Countershaft Assembly While Removing Counterdriven Gear Nut
    G01384626Courtesy of GENERAL MOTORS CORP.
  100. Remove the thrust bearing from the transaxle case.
    Fig 77: Removing Thrust Bearing From Transaxle Case
    G01384627Courtesy of GENERAL MOTORS CORP.
  101. Pull out the counter shaft from the transaxle case.
    Fig 78: Removing Counter Shaft
    G01384628Courtesy of GENERAL MOTORS CORP.
  102. Remove the needle bearing from the counter shaft assembly.
    Fig 79: Removing Counter Shaft Assembly Needle Bearing
    G01384629Courtesy of GENERAL MOTORS CORP.
  103. Install a dial indicator (1) on the underdrive clutch piston.
    Fig 80: Installing Dial Indicator On Underdrive Clutch Piston
    G01384630Courtesy of GENERAL MOTORS CORP.

    Important:  If the piston stroke is not within 1.5-1. mm (0.059-0.075 in). Install a new flange during assembly.

  104. While applying and releasing compressed air at a pressure of 392-785 kPa (57-114 psi) measure the piston stroke.
    Fig 81: Measuring Piston Stroke Using Compressed Air
    G01384631Courtesy of GENERAL MOTORS CORP.
  105. Remove the underdrive clutch assembly from the transxle case.
  106. Remove the underdrive 1 way clutch retainer from the transaxle case.
    Fig 82: Identifying Underdrive 1 Way Clutch Retainer
    G01384632Courtesy of GENERAL MOTORS CORP.
  107. Hold the 1 way clutch drum (1) and turn the 1 way clutch (2). The 1 way clutch should turn freely counterclockwise (3) and should lock if turned clockwise (4).
    Fig 83: Checking 1 Way Clutch Rotation
    G01384633Courtesy of GENERAL MOTORS CORP.
  108. Remove the 1 way clutch assembly and the underdrive clutch drum thrust washer (1) from the underdrive clutch drum.
    Fig 84: Removing Underdrive Clutch Drum Thrust Washer
    G01384634Courtesy of GENERAL MOTORS CORP.
  109. Remove the 2 overdrive clutch drum oil seal rings from the transaxle case.
    Fig 85: Removing Overdrive Clutch Drum Oil Seal Rings
    G01384635Courtesy of GENERAL MOTORS CORP.
  110. Install a dial indicator on the underdrive brake pack.

    Important:  If the clearance is not within 1.15-1.97 mm (0.0453-0.0766 in). Inspect the discs.

  111. While applying compressed air, measure the pack clearance.
    Fig 86: Measuring Underdrive Brake Pack Clearance Using Compressed Air
    G01384636Courtesy of GENERAL MOTORS CORP.
  112. Using a press, compress the flange until the snap ring is accessible.
  113. Using a screwdriver, remove the underdrive clutch flange snap ring from the transaxle case.
    Fig 87: Removing Underdrive Clutch Flange Snap Ring Using Flat Bladed Tool
    G01384637Courtesy of GENERAL MOTORS CORP.
  114. Remove the flange, plates and underdrive clutch discs.
    Fig 88: Removing Underdrive Clutch Discs, Plates & Flange
    G01384638Courtesy of GENERAL MOTORS CORP.
  115. Check the sliding surfaces of the plates and clutch discs. If the sliding surfaces of the discs, plates and flanges are worn, discolored, or if a part of the printed numbers are defaced, replace all the discs and plates.
    Fig 89: Identifying Underdrive Clutch Discs Printed Number Location
    G01384639Courtesy of GENERAL MOTORS CORP.
  116. Remove the underdrive brake return spring sub-assembly from the transaxle case.
    Fig 90: Removing Underdrive Brake Return Spring Sub-Assembly
    G01384640Courtesy of GENERAL MOTORS CORP.
  117. Using compressed air at low pressure 98 kPa (14 psi) push out the underdrive brake piston from the transaxle case into a shop towel.
    Fig 91: Removing Underdrive Brake Piston Using Compressed Air
    G01384641Courtesy of GENERAL MOTORS CORP.
  118. Using a screwdriver, remove the 2 O-ring from the underdrive brake piston.
    Fig 92: Removing Underdrive Brake Piston O-Ring
    G01384642Courtesy of GENERAL MOTORS CORP.
  119. Remove the 2 bolts, pawl stopper plate, torsion spring and spring guide sleeve from the transaxle case.
    Fig 93: Removing Pawl Stopper Plate, Torsion Spring, Spring Guide Sleeve & Bolts
    G01384643Courtesy of GENERAL MOTORS CORP.
  120. Remove the bolt and pawl shaft clamp from the transaxle case.
    Fig 94: Removing Pawl Shaft Clamp & Bolt
    G01384644Courtesy of GENERAL MOTORS CORP.
  121. Remove the parking lock pawl shaft and parking lock pawl from the transaxle case.
    Fig 95: Removing Parking Lock Pawl Shaft & Parking Lock Pawl
    G01384645Courtesy of GENERAL MOTORS CORP.
  122. Remove the spring guide sleeve from the transaxle case.
    Fig 96: Removing Spring Guide Sleeve
    G01384646Courtesy of GENERAL MOTORS CORP.
  123. Remove the cam guide sleeve from the transaxle case.
    Fig 97: Removing Cam Guide Sleeve
    G01384647Courtesy of GENERAL MOTORS CORP.
  124. Using a TORX® bit, remove the 7 screws.
    Fig 98: Removing Transmission Case Plate No. 2 Screws
    G01384648Courtesy of GENERAL MOTORS CORP.
  125. Remove the 2 bolts.
  126. Remove the transmission case plate No. 2 and the case plate gasket from the transaxle case.
    Fig 99: Removing Transmission Case Plate No. 2 Bolts
    G01384649Courtesy of GENERAL MOTORS CORP.
  127. Remove the B-4 accumulator piston and spring from the transaxle case.
  128. Remove the 2 O-rings from the piston.
  129. Remove the bolt and the transmission case plate No. 3 from the transaxle case.
    Fig 100: Removing B-4 Accumulator Piston & Spring
    G01384650Courtesy of GENERAL MOTORS CORP.
  130. Using a suitable puller, remove the counterdriven gear roller bearing from the transaxle case.
    Fig 101: Removing Counterdriven Gear Roller Bearing With Puller
    G01384651Courtesy of GENERAL MOTORS CORP.
  131. Remove the bolts and transaxle apply tube clamps from the transaxle case.
    Fig 102: Removing Transaxle Apply Tube Clamps & Bolts
    G01384652Courtesy of GENERAL MOTORS CORP.
  132. Using a screwdriver, remove the lube apply tube from the transaxle case.
  133. Using a screwdriver remove the differential gear apply tube from the transaxle case.
    Fig 103: Removing Differential Gear Apply Tube
    G01384653Courtesy of GENERAL MOTORS CORP.
  134. Remove the bolt and the underdrive roller bearing retainer from the transaxle case.
    Fig 104: Removing Underdrive Roller Bearing Retainer & Bolt
    G01384654Courtesy of GENERAL MOTORS CORP.
  135. Using a puller, remove the roller bearing from the transaxle housing.
    Fig 105: Removing Underdrive Roller Bearing Using Puller
    G01384655Courtesy of GENERAL MOTORS CORP.
  136. Using a screwdriver, remove the housing oil seal from the transaxle case.
    Fig 106: Removing Housing Oil Seal
    G01384656Courtesy of GENERAL MOTORS CORP.
  137. Using a screwdriver, remove the transaxle case oil seal from the transaxle case.
  138. Using a bearing puller, remove the front drive pinion roller bearing from the differential case.
  139. Using a bearing puller, remove the rear drive pinion roller bearing from the differential case.
    Fig 107: Removing Transaxle Case Oil Seal
    G01384657Courtesy of GENERAL MOTORS CORP.
  140. Using a press, drive out the front pinion front roller bearing outer race.
    Fig 108: View Of Front Pinion Front Roller Bearing Outer Race
    G01384658Courtesy of GENERAL MOTORS CORP.
  141. Drive out the front drive pinion rear roller bearing outer race and adjusting shim from the transaxle case.
    Fig 109: Driving Out Front Drive Pinion Rear Roller Bearing Outer Race & Shim
    G01384659Courtesy of GENERAL MOTORS CORP.
  142. Using a press, install a new front drive pinion rear roller bearing on the differential case.
    Fig 110: Sectional View Of Front Drive Pinion Rear Roller Bearing
    G01384660Courtesy of GENERAL MOTORS CORP.
  143. Place the adjusting shim in the transaxle case.
  144. Using a press, install a new front drive pinion rear roller bearing outer race in the transaxle case.
    Fig 111: Sectional View Of Front Drive Pinion Rear Roller Bearing Outer Race
    G01384661Courtesy of GENERAL MOTORS CORP.
  145. Install the speedometer drive gear on the differential case.
    Fig 112: Installing Speedometer Drive Gear
    G01384662Courtesy of GENERAL MOTORS CORP.
  146. Using a press, install a new front drive pinion front roller bearing in the transaxle case.
    Fig 113: Sectional View Of Front Drive Pinion Front Roller Bearing
    G01384663Courtesy of GENERAL MOTORS CORP.
  147. Using a press, install a new front drive pinion front roller bearing outer race in the transaxle case.
    Fig 114: Sectional View Of Front Drive Pinion Front Roller Bearing Outer Race
    G01384664Courtesy of GENERAL MOTORS CORP.
  148. Install a new transaxle case oil seal.
  149. Coat the lip of the seal with Multi-Purpose grease or equivalent.
    Fig 115: Installing Transaxle Case Oil Seal
    G01384665Courtesy of GENERAL MOTORS CORP.
  150. Install a new transaxle oil seal in the transaxle case.
  151. Coat the lip of the seal with Multi-Purpose grease or equivalent.
    Fig 116: Installing Transaxle Oil Seal
    G01384666Courtesy of GENERAL MOTORS CORP.
  152. Using a press, install the underdrive roller bearing in the transaxle housing.
    Fig 117: Installing Underdrive Roller Bearing
    G01384667Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  153. Install the roller bearing retainer with the bolt to the transaxle housing.

    Tighten 

    Tighten the bolt to 17 N.m (13 lb ft).

    Fig 118: Installing Roller Bearing Retainer
    G01384668Courtesy of GENERAL MOTORS CORP.
  154. Using a soft faced hammer, install the differential gear lube apply tube.
  155. Using a soft faced hammer, install the transaxle apply tube in the transaxle housing.
    Fig 119: Installing Differential Gear Lube Apply Tube Using Soft Faced Hammer
    G01384669Courtesy of GENERAL MOTORS CORP.
  156. Install the transaxle apply tube clamps and bolts in the transaxle housing.

    Tighten 

    Tighten the bolts to 5.5 N.m (49 lb in).

    Fig 120: Installing Transaxle Apply Tube Clamps & Bolts
    G01384670Courtesy of GENERAL MOTORS CORP.
  157. Using a press, install the counterdriven gear roller bearing in the transaxle case.
    Fig 121: Installing Counterdriven Gear Roller Bearing
    G01384671Courtesy of GENERAL MOTORS CORP.
  158. Coat the new B-4 accumulator O-rings with T-IV automatic transmission fluid.
  159. Install the O-rings on the accumulator piston.
  160. Install accumulator piston and spring in the transaxle case.
    Fig 122: Installing B-4 Accumulator & Spring
    G01384672Courtesy of GENERAL MOTORS CORP.
  161. Install the transmission case plate and gasket on the transaxle case.
  162. Install the 2 bolts.

    Tighten 

    Tighten the bolts to 10 N.m (7 lb ft).

    Fig 123: Installing Transmission Case Plate, Bolts & Gasket
    G01384673Courtesy of GENERAL MOTORS CORP.
  163. Apply Threadlocker 242 GM P/N 12345382 (Canadian P/N 10953459) or the equivalent to the 7 retaining screws.
  164. Using a TORX® bit, install the screws.

    Tighten 

    Tighten the screws to 10 N.m (7 lb ft).

    Fig 124: Installing Transmission Case Plate Screws
    G01384674Courtesy of GENERAL MOTORS CORP.
  165. Install the cam guide sleeve in the transaxle case.
    Fig 125: Installing Cam Guide Sleeve
    G01384675Courtesy of GENERAL MOTORS CORP.
  166. Install the spring guide sleeve with the protruding portion facing up.
    Fig 126: Installing Spring Guide Sleeve Protruding Portion Facing Up
    G01384676Courtesy of GENERAL MOTORS CORP.
  167. Place the pawl stopper plate on the protruding portion of the lock sleeve in the transaxle case.
    Fig 127: Aligning Pawl Stopper Plate On Lock Sleeve In Transaxle Case
    G01384677Courtesy of GENERAL MOTORS CORP.
  168. Install the spring guide sleeve and torsion spring with the 2 bolts.

    Tighten 

    Tighten the bolts to 13 N.m (9 lb ft).

    Fig 128: Installing Spring Guide Sleeve, Bolts & Torsion Spring
    G01384678Courtesy of GENERAL MOTORS CORP.
  169. Install the parking lock pawl in the transaxle case.
    Fig 129: Installing Parking Lock Pawl
    G01384679Courtesy of GENERAL MOTORS CORP.
  170. Install the parking lock pawl shaft with the clamp groove (1) upward, then install the pawl shaft clamp and the 2 bolts.

    Tighten 

    Tighten the bolts to 5.5 N.m (49 lb in).

    Fig 130: Installing Parking Lock Pawl Shaft With Clamp Groove Upwards
    G01384680Courtesy of GENERAL MOTORS CORP.
  171. Coat the new O-rings with T-IV automatic transmission fluid.
  172. Install the O-rings on the underdrive brake piston.
    Fig 131: Installing Underdrive Brake Piston O-Rings
    G01384681Courtesy of GENERAL MOTORS CORP.
  173. Place the underdrive brake piston into the case with the cup side up, being careful not to damage the O-rings.
    Fig 132: Aligning Underdrive Brake Piston Cup Side Up
    G01384682Courtesy of GENERAL MOTORS CORP.
  174. Install the underdrive brake return spring sub-assembly in the transaxle case.
    Fig 133: Installing Underdrive Brake Return Spring Sub-Assembly
    G01384683Courtesy of GENERAL MOTORS CORP.

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

  175. Install the plates, underdrive clutch discs and flange in the following order: P - D - P - D - P - D - F.
    Fig 134: Installing Underdrive Clutch Discs, Plates & Flange
    G01384684Courtesy of GENERAL MOTORS CORP.
  176. Using a press, compress the flange and install the underdrive clutch flange snap ring in the transaxle case.
    Fig 135: Installing Underdrive Clutch Flange Snap Ring
    G01384685Courtesy of GENERAL MOTORS CORP.

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

  177. Using a dial indicator, measure the underdrive brake pack clearance.
    Fig 136: Measuring Pack Clearance Using Compressed Air
    G01384686Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 137: Installing Overdrive Clutch Drum Oil Seal Rings
    G01384687Courtesy of GENERAL MOTORS CORP.
  180. Install the underdrive 1 way clutch assembly and the underdrive clutch drum trust washer in the transaxle case.
    Fig 138: Installing Underdrive 1 Way Clutch Retainer
    G01384688Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 139: Locating Underdrive 1 Way Clutch Retainer
    G01384689Courtesy of GENERAL MOTORS CORP.
  185. Turn the underdrive clutch assembly. The clutch assembly should turn freely counterclockwise (1) and should lock clockwise (2).
    Fig 140: Checking Underdrive Clutch Assembly Rotation
    G01384690Courtesy of GENERAL MOTORS CORP.
  186. Install the assembled bearing and race with the thrust needle roller bearing facing upward
    Fig 141: Installing Assembled Bearing Race With Thrust Needle Roller Bearing Facing Upward
    G01384691Courtesy of GENERAL MOTORS CORP.
  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 in).
    Fig 142: Measuring Sleeve Height To Inner Race Using Calipers
    G01384692Courtesy of GENERAL MOTORS CORP.
  188. Install a dial indicator on the underdrive clutch piston.
    Fig 143: Installing Dial Indicator On Underdrive Clutch Piston
    G01384693Courtesy of GENERAL MOTORS CORP.

    Important:  If the piston stroke is not within 1.5-1.9 mm (0.059-0.075 in). 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).

  189. While applying and releasing compressed air at a pressure of 392-785 kPa (57-114 psi) measure the underdrive clutch piston stroke.
    Fig 144: Measuring Underdrive Clutch Piston Stroke Using Compressed Air
    G01384694Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 145: Removing Underdrive Planetary Sun Gear
    G01384695Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 146: Installing Underdrive Planetary Sun Gear Sub-Assembly
    G01384696Courtesy of GENERAL MOTORS CORP.
  197. Install the countershaft assembly in the transaxle case.
    Fig 147: Installing Countershaft Assembly In Transaxle Case
    G01384697Courtesy of GENERAL MOTORS CORP.
  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 in).
  199. Install the new counterdrive gear bearing on the counterdrive gear.
  200. Install a new snap ring to retain the bearing.
    Fig 148: Measuring Between Tip Of Countershaft & Bolt Seat Of Clutch Support
    G01384698Courtesy of GENERAL MOTORS CORP.
  201. Using a press, install the counter drive gear.
    Fig 149: Installing Counter Drive Gear
    G01384699Courtesy of GENERAL MOTORS CORP.
  202. Install the intermediate shaft sub-assembly in the transaxle case.
    Fig 150: Installing Intermediate Shaft Sub-Assembly
    G01384700Courtesy of GENERAL MOTORS CORP.
  203. While holding the counter drive gear, install a new counter drive gear nut.

    Tighten 

    Tighten the nut to 180 N.m (133 lb ft).

    Fig 151: Securing Counter Drive Gear While Installing Counter Drive Gear Nut
    G01384701Courtesy of GENERAL MOTORS CORP.

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

  204. Using a torque wrench, measure the starting torque of the counter drive gear.

    Starting Torque 

    1. 0.11-0.70 N.m (0.9-6.1 lb in).

    Rotating Torque 

    1. 0.04-0.30 N.m (0.3-2.6 lb in).
    Fig 152: Measuring Starting & Rotating Torque Of Counter Drive Gear
    G01384702Courtesy of GENERAL MOTORS CORP.
  205. Using a pin punch and hammer, stake the counter drive gear nut.
    Fig 153: Staking Counter Drive Gear Nut
    G01384703Courtesy of GENERAL MOTORS CORP.
  206. Install the needle roller bearing in the transaxle case.
    Fig 154: Installing Needle Roller Bearing In Transaxle Case
    G01384704Courtesy of GENERAL MOTORS CORP.
  207. Using a press, install the counter driven gear on the transaxle case.
  208. Install a new counter driven gear nut.

    Tighten 

    1. Tighten the nut to 180 N.m (133 lb ft).
    Fig 155: Installing Counter Driven Gear
    G01384705Courtesy of GENERAL MOTORS CORP.
  209. Using a dial indicator, measure the endplay of the countershaft.

    Endplay 

    1. Endplay should be within 0.2-0.9 mm (0.008-0.035 in).
    Fig 156: Measuring Countershaft Endplay Using Dial Indicator
    G01384706Courtesy of GENERAL MOTORS CORP.
  210. Using a pin punch and hammer, stake the counter driven gear nut.
    Fig 157: Staking Counter Driven Gear Nut
    G01384707Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 158: Identifying Sealant Application Area On Transaxle Case Cover
    G01384708Courtesy of GENERAL MOTORS CORP.
  213. Install bolts A: 25 mm (0.98 in) in length into the positions shown.
  214. Install bolts B: 32 mm (1.26 in) in length into the positions shown.

    Tighten 

    1. Tighten all 13 bolts to 10 N.m (7 lb ft).
    Fig 159: Identifying Transaxle Case Cover Bolt Locations
    G01384709Courtesy of GENERAL MOTORS CORP.
  215. Ensure that the intermediate shaft sub-assembly turns smoothly.
    Fig 160: Checking Intermediate Shaft Sub-Assembly Rotation
    G01384710Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 161: Installing 1st & Reverse Brake Piston O-Rings
    G01384711Courtesy of GENERAL MOTORS CORP.
  218. Install the 1st and reverse brake piston into the bore of the case, facing the spring seats upward.
    Fig 162: Installing 1st & Reverse Brake Piston
    G01384712Courtesy of GENERAL MOTORS CORP.
  219. Install the 1st and reverse brake return spring and snap ring into position.
    Fig 163: Installing 1st & Reverse Brake Return Spring & Snap Ring
    G01384713Courtesy of GENERAL MOTORS CORP.
  220. Using a press, compress the 1st and reverse brake return spring sub-assembly.
  221. Using snap ring pliers, install the snap ring.
    Fig 164: Compressing 1st & Reverse Brake Return Spring Sub-Assembly
    G01384714Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 165: Installing 1st & Reverse Brake Clutch Discs
    G01384715Courtesy of GENERAL MOTORS CORP.
  223. Install the outer flange with the flat side facing downward.
    Fig 166: Installing Outer Flange With Flat Side Down
    G01384716Courtesy of GENERAL MOTORS CORP.

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

  224. Using a screwdriver, install the snap ring to the transaxle case.
    Fig 167: Installing Snap Ring Into Transaxle Case
    G01384717Courtesy of GENERAL MOTORS CORP.

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

  225. 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 in).
    Fig 168: Measuring 1st & Reverse Brake Pack Clearance Using Feeler Gage
    G01384718Courtesy of GENERAL MOTORS CORP.
  226. Coat the needle roller bearing with petroleum jelly, then install the bearing on the ring gear.
    Fig 169: Installing Needle Roller Bearing On Ring Gear
    G01384719Courtesy of GENERAL MOTORS CORP.

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

  227. Coat the planetary gear thrust washer No. 2 with petroleum jelly, then install the thrust washer on the rear planetary gear assembly.
    Fig 170: Installing Thrust Washer On Planetary Gear Assembly
    G01384720Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 171: Installing Rear Planetary Gear Assembly
    G01384721Courtesy of GENERAL MOTORS CORP.
  229. Check that (1) of the rear planetary gear assembly is below the upper surface of the flange.
    Fig 172: Checking Alignment Of Rear Planetary Gear Assembly
    G01384722Courtesy of GENERAL MOTORS CORP.
  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).
    Fig 173: Checking Rear Planetary Gear Assembly Rotation
    G01384723Courtesy of GENERAL MOTORS CORP.
  233. Coat the planetary gear thrust washer No.2 with petroleum jelly, then install it on the planetary gear.
    Fig 174: Installing Planetary Gear Thrust Washer
    G01384724Courtesy of GENERAL MOTORS CORP.
  234. Ensure the end gap of the snap ring is not aligned with the cut outs.
    Fig 175: Checking Snap Ring End Gap To Cut Out Alignment
    G01384725Courtesy of GENERAL MOTORS CORP.
  235. Install the 2nd brake clutch flange with the flat side facing upward.
    Fig 176: Installing 2nd Brake Clutch Flange
    G01384726Courtesy of GENERAL MOTORS CORP.
  236. Install the 2nd brake clutch discs and plates, in the following order: D - P - D - P - D - P.
    Fig 177: Installing 2nd Brake Clutch Discs & Plates
    G01384727Courtesy of GENERAL MOTORS CORP.
  237. Install each of the 2nd brake piston return spring sub-assembly over the protrusions in the transaxle case.
    Fig 178: Installing 2nd Brake Piston Return Spring Sub-Assembly
    G01384728Courtesy of GENERAL MOTORS CORP.
  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 

    1. Tighten the bolt to 5.5 N.m (49 lb in).
    Fig 179: Installing 2nd Coast Brake Band Guide Plate Retainer & Brake Band Plate Retainer
    G01384729Courtesy of GENERAL MOTORS CORP.
  240. Align the groove of the drum with the bolt and place the 2nd brake piston assembly into the transaxle case.
    Fig 180: Aligning Drum Groove With Bolt
    G01384730Courtesy of GENERAL MOTORS CORP.
  241. Place both ends of the snap ring in the groove, then set the snap ring in the transaxle case.

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

  242. While compressing the piston return springs over the drum with hammer handles, install the snap ring.
    Fig 181: Compressing Piston Return Springs Using Hammer Handles
    G01384731Courtesy of GENERAL MOTORS CORP.
  243. Using compressed air, check that the 2nd brake piston moves smoothly.
    Fig 182: Checking 2nd Brake Piston Action Using Compressed Air
    G01384732Courtesy of GENERAL MOTORS CORP.
  244. Using a screwdriver, align the flukes of the discs in the 2nd brake.
    Fig 183: Aligning Flukes Of Discs In 2nd Brake
    G01384733Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 184: Sectional View Of 1 Way Clutch
    G01384734Courtesy of GENERAL MOTORS CORP.
  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 in).
    Fig 185: Checking 2nd Brake Hub & Rear Planetary Gear Clearance
    G01384735Courtesy of GENERAL MOTORS CORP.
  247. Coat the planetary carrier thrust washer No. 3 with petroleum jelly, then install the thrust washer on the sun gear input drum.
    Fig 186: Installing Planetary Carrier Thrust Washer No. 3
    G01384736Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 187: Rotating Sun Gear Clockwise In Sun Gear Input Drum
    G01384737Courtesy of GENERAL MOTORS CORP.
  249. Coat the thrust roller bearing and thrust bearing race with petroleum jelly, then install them on the front planetary gear assembly.
    Fig 188: Installing Thrust Roller Bearing & Thrust Bearing Race Into Planetary Gear Assembly
    G01384738Courtesy of GENERAL MOTORS CORP.
  250. Install the front planetary gear assembly.
    Fig 189: Installing Front Planetary Gear Assembly
    G01384739Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 190: Installing Thrust Bearing Race & Roller Bearing Onto Front Planetary Ring Gear Assembly
    G01384740Courtesy of GENERAL MOTORS CORP.
  253. Install the front planetary ring gear in the transaxle case.
    Fig 191: Installing Front Planetary Ring Gear
    G01384741Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 192: Checking Alignment Of Ring Gear Flange Bushing With Intermediate Shaft Shoulder
    G01384742Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 193: Installing Thrust Roller Bearing & Bearing Race On Tip Of Ring Gear Flange
    G01384743Courtesy of GENERAL MOTORS CORP.
  256. Place the 2nd coast brake band assembly into the transaxle case.
  257. Install the 2nd coast brake band pin in the transaxle case.
    Fig 194: Installing 2nd Coast Brake Band Pin
    G01384744Courtesy of GENERAL MOTORS CORP.
  258. Coat the thrust roller bearing with petroleum jelly, then install the bearing on the forward clutch drum.
    Fig 195: Installing Thrust Roller Bearing On Forward Clutch Drum
    G01384745Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 196: Installing Clutch Drum Thrust Washer With Oil Groove Facing Upward
    G01384746Courtesy of GENERAL MOTORS CORP.
  260. Using a screwdriver, align the flukes of the discs in the direct clutch.
    Fig 197: Aligning Flukes Of Direct Clutch Discs Using Flat Bladed Tool
    G01384747Courtesy of GENERAL MOTORS CORP.

    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.

  261. Mesh the hub with flukes of the direct clutch while turning the forward clutch drum.
    Fig 198: Cross Sectional View Of Forward Clutch Drum
    G01384748Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 199: Installing Direct Clutch & Forward Clutch Assembly Into Transaxle Case
    G01384749Courtesy of GENERAL MOTORS CORP.
  264. Using a feeler gage, check the clearance between points (1) and (2). The clearance should be 3 mm (0.118 in).
    Fig 200: Checking Disc Clearance Using Feeler Gage
    G01384750Courtesy of GENERAL MOTORS CORP.
  265. Coat the 2 new O-rings with T-IV automatic transmission fluid, then install the O-rings on the 2nd coast brake cover.
    Fig 201: Installing 2nd Coast Brake Cover O-Rings
    G01384751Courtesy of GENERAL MOTORS CORP.
  266. Install the spring 2nd coast brake piston assembly and 2nd coast brake cover into the transaxle case.
    Fig 202: Installing 2nd Coast Brake Piston Assembly & Cover
    G01384752Courtesy of GENERAL MOTORS CORP.
  267. Using snap ring pliers, install the 2nd coast brake piston snap ring.
    Fig 203: Installing 2nd Coast Brake Piston Snap Ring
    G01384753Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 204: Applying Paint To 2nd Coast Brake Piston Rod At Case
    G01384754Courtesy of GENERAL MOTORS CORP.

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

  269. While applying and releasing compressed air at a pressure of 392-785 kPa (57-114 psi) measure the piston stroke.
    Fig 205: Checking Piston Stroke Using Compressed Air
    G01384755Courtesy of GENERAL MOTORS CORP.
  270. Using a soft faced hammer, install the governor pressure tube in the transaxle case.
    Fig 206: Installing Governor Pressure Tube In Transaxle Case
    G01384756Courtesy of GENERAL MOTORS CORP.
  271. Install the transaxle apply tube clamp and bolt in the transaxle case.

    Tighten 

    1. Tighten the bolt to 5.5 N.m (49 lb in).
    Fig 207: Installing Transaxle Apply Tube Clamp & Bolt
    G01384757Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 208: Installing Oil Pump O-Ring
    G01384758Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 209: Installing Oil Pump
    G01384759Courtesy of GENERAL MOTORS CORP.
  275. Install the 6 bolts.

    Tighten 

    1. Tighten the bolts to 25 N.m (18 lb ft).
    Fig 210: Installing Oil Pump Retaining Bolts
    G01384760Courtesy of GENERAL MOTORS CORP.

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

  276. Using a dial indicator, measure the end play of the input shaft.
    Fig 211: Measuring Input Shaft End Play Using Dial Indicator
    G01384761Courtesy of GENERAL MOTORS CORP.
  277. Ensure that the input shaft rotates smoothly.
    Fig 212: Checking Input Shaft Rotation
    G01384762Courtesy of GENERAL MOTORS CORP.
  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 

    1. Tighten the bolt to 10 N.m (7 lb ft).
    Fig 213: Installing Governor Apply Gasket No. 2
    G01384763Courtesy of GENERAL MOTORS CORP.
  280. Install the differential assembly into the transaxle case.
    Fig 214: Installing Differential Assembly
    G01384764Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 215: Identifying Sealant Application Areas On Transaxle Case Cover
    G01384765Courtesy of GENERAL MOTORS CORP.
  283. Apply Threadlocker 242 GM P/N 12345382 or the equivalent to the threads of bolts (2). These bolts are 35 mm (1.38 in) in length.
  284. Install the (2) bolts.

    Tighten 

    1. Tighten the bolts to 28 N.m (20 lb ft).
  285. Install the (1) bolts.

    Tighten 

    1. Tighten the bolts to 28 N.m (20 lb ft).
    Fig 216: Identifying Transaxle Case Cover Bolt Location
    G01384766Courtesy of GENERAL MOTORS CORP.
  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.

    Starting Preload 

    • New Bearing: 0.8-1.4 N.m (6.9-12.2 lb in).
    • Used Bearing: 0.04-0.7 N.m (3.5-6.1 lb in).

    Important:  The preload will change about 0.3-0.4 N.m (2.6-2.9 lb in) according to a change in shim thickness of 0.05 mm (0.0020 in).

  288. If the preload is not within specification, remove the differential from the transaxle case. Select a new transaxle case side adjusting shim. Refer to General Specifications .
    Fig 217: Measuring Preload Of Side Bearing
    G01384767Courtesy of GENERAL MOTORS CORP.
  289. Using a 14 mm (0.55 in) socket and hammer, drive in a new manual valve lever shaft oil seal.
  290. Apply multi-purpose grease to the seal lip.
    Fig 218: Installing Manual Valve Lever Shaft Oil Seal
    G01384768Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 219: Installing Manual Valve Lever Shaft
    G01384769Courtesy of GENERAL MOTORS CORP.

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

  293. Install the retainer spring.
    Fig 220: Installing Retainer Spring
    G01384770Courtesy of GENERAL MOTORS CORP.
  294. Using a pin punch and hammer, install the roll pin.
  295. Position the spacer, then stake the spacer.
    Fig 221: Staking Pin Spacer
    G01384771Courtesy of GENERAL MOTORS CORP.
  296. Coat the new O-rings with T-IV automatic transmission, them install the O-rings on the accumulator pistons.

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

  297. Install the accumulator springs and pistons in the transaxle case.
    Fig 222: Identifying Installation Sequence Of Accumulator Springs & Pistons
    G01384772Courtesy of GENERAL MOTORS CORP.
  298. Install a new brake drum gasket until it makes contact with the 2nd brake drum.
    Fig 223: Installing Brake Drum Gasket
    G01384773Courtesy of GENERAL MOTORS CORP.
  299. Install the new governor apply gasket No. 1 in the transaxle case.
    Fig 224: Installing New Governor Apply Gasket No. 1
    G01384774Courtesy of GENERAL MOTORS CORP.
  300. Install the check ball body and spring in the transaxle case.
    Fig 225: Installing Check Ball Body & Spring
    G01384775Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 226: Installing Transmission Wire Harness Connector
    G01384776Courtesy of GENERAL MOTORS CORP.
  303. Install the connector retaining bolt.

    Tighten 

    1. Tighten the bolt to 5.5 N.m (49 lb in).
    Fig 227: Installing Transmission Wire Harness Connector Retaining Bolt
    G01384777Courtesy of GENERAL MOTORS CORP.
  304. Connect the manual valve connecting rod to the manual valve lever.
    Fig 228: Connecting Manual Valve Connecting Rod To Manual Valve Lever
    G01384778Courtesy of GENERAL MOTORS CORP.

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

  305. Install the valve body with the 17 retaining bolts.
    Fig 229: Identifying Valve Body Retaining Bolt Installation Locations
    G01384779Courtesy of GENERAL MOTORS CORP.
  306. Connect the solenoid connectors.
    Fig 230: Connecting Solenoid Connectors
    G01384780Courtesy of GENERAL MOTORS CORP.
  307. Install the manual detent spring sub-assembly.
  308. Install the manual detent spring cover and bolt.

    Tighten 

    1. Tighten the bolt to 10 N.m (7 lb ft).
    Fig 231: Installing Manual Detent Spring Sub-Assembly & Bolt
    G01384781Courtesy of GENERAL MOTORS CORP.

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

  309. Install the valve body oil filter and gasket, then install the 3 bolts.

    Tighten 

    1. Tighten the bolts to 10 N.m (7 lb ft).
    Fig 232: Identifying Valve Body Oil Filter Retaining Bolt Installation Locations
    G01384782Courtesy of GENERAL MOTORS CORP.
  310. Install the 2 transaxle oil pan magnets on the oil pan.
    Fig 233: View Of Transaxle Oil Pan Magnets
    G01384783Courtesy of GENERAL MOTORS CORP.
  311. Install a new oil pan gasket and oil pan on the transaxle case.
  312. Install the 18 oil pan retaining bolts.

    Tighten 

    1. Tighten the bolts to 5.3 N.m (47 lb in)
    Fig 234: Installing Oil Pan Retaining Bolts
    G01384784Courtesy of GENERAL MOTORS CORP.
  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 

    1. Tighten the unions to 28 N.m (20 lb ft).
    Fig 235: Installing Oil Cooler Pipe Unions
    G01384785Courtesy of GENERAL MOTORS CORP.
  316. Install the PNP switch to the manual shift lever
  317. Place a new lock washer and nut on the manual shift lever.

    Tighten 

    1. Tighten the nut to 7.0 N.m (62 lb in).
  318. Temporarily install the 2 PNP switch retaining bolts.
    Fig 236: Installing PNP Switch & Retaining Bolts
    G01384786Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 237: Identifying Transmission Control Shift Lever In Neutral Position
    G01384787Courtesy of GENERAL MOTORS CORP.
  322. Align the groove (1) with neutral line (2).
  323. Tighten the 2 bolts.

    Tighten 

    1. Tighten the bolts to 5.5 N.m (49 lb in).
  324. Install the transmission control shaft lever with the nut and washer.

    Tighten 

    1. Tighten the nut to 12 N.m (8 lb ft).
  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.
    Fig 238: Aligning Groove With Neutral Line
    G01384788Courtesy of GENERAL MOTORS CORP.
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