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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1829 (Automatic Transmission - 5AT - Introduction (2 Of 2)) >> Repair Instructions >> Repair Instructions - Off Vehicle >> 1st and 2nd Clutch Shaft Assemble

1st and 2nd Clutch Shaft Assemble

WARNING: This page is about a different car, the 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

    Fig 1: Coast Clutch Hub, Coast Sprag Assembly & 1st Drive Gear
    GM1507162Courtesy of GENERAL MOTORS CORP.
  1. If disassembled, install the 1st drive gear (726) in the coast sprag assembly (725).
    • Push in on the sprag rollers
    • Keep the 1st drive gear square to the sprag assembly
    • The components will slide together without being forced
  2. Partially install the coast clutch hub (724) in the coast sprag assembly (725).
    3. Fig 2: Installing The 1st Coast Clutch Hub & 1st Drive Gear Using EN 46342, DT 46516 & A Hydraulic Press
    GM1203947Courtesy of GENERAL MOTORS CORP.
  3. Using the EN 46342  (1) and the DT 46427  (2) with a hydraulic press, complete the installation of the coast clutch hub (724) in the coast sprag assembly (725). See Special Tools .
    4. Fig 3: Inspecting The Operation Of 1st/Coast Hub & Coast Sprag Assembly
    GM1203945Courtesy of GENERAL MOTORS CORP.
  4. Inspect the operation of the 1st/coast hub and coast sprag assembly (752).
    • Hold the coast clutch (724) and turn clockwise the 1st drive gear (726). The assembly should turn freely clockwise.
    • Turn the 1st drive gear (726) the opposite direction, counterclockwise. The assembly should lock.
    5. Fig 4: Installing 2nd Clutch Assembly & 32 mm 2nd Clutch Housing Retaining Ring
    GM1203948Courtesy of GENERAL MOTORS CORP.
  5. Lubricate all of the components with automatic transmission fluid during assembly.
  6. Wrap the splines on the shaft end of the 1st/2nd clutch shaft with tape. This is to prevent damage to the seals during installation.
  7. Install the two new 31.2 x 1.9 mm 2nd clutch housing fluid passage seals (737).
  8. Remove the tape.
    9. Fig 5: Exploded View Of 1st/2nd Clutch Shaft & Components
    GM1679630Courtesy of GENERAL MOTORS CORP.
  9. Install the following on the shaft:
    • The 2nd drive gear thrust bearing (731)
    • The 2nd drive gear inner bearing (733)
    • The 2nd drive with clutch hub and park gear (732)
    • The 2nd drive gear thrush bearing (731)
    • The splined washer (734) in the direction as shown
    • The 2nd clutch housing assembly (756)
  10. Install the 32 mm 2nd clutch housing retaining ring (751).
    11. Fig 6: 1st/2nd Clutch Shaft & Components
    GM1679668Courtesy of GENERAL MOTORS CORP.
  11. Install the following on the 1st/2nd clutch shaft (736):
    • The 1st/2nd clutch shaft drive gear (730) in the direction shown
    • The 1st drive gear thrust bearing (727)
    • The 1st drive gear bearing race (729). Install with the lube holes in the up position. Align the race with the lube groove of the 1st and 2nd clutch shaft (736).
    • The 1st drive gear inner bearing (728)
    • The 1st/coast hub and coast sprag assembly (752)
    • The 1st/coast clutch thrust bearing (723)
    • The 1st/coast clutch hub selective thrust bearing washer (722) in the direction shown
    12. Fig 7: 1st And Coast Clutch Housing & 1st And 2nd Clutch Shaft
    GM1345512Courtesy of GENERAL MOTORS CORP.
  12. Wrap the splines on the 1st and 2nd clutch shaft (736) with tape.
  13. Install 3 new 1st and coast clutch housing 26.7 x 1.9 mm O-ring seals (735) in the 1st coast clutch O-ring grooves of the 1st and 2nd clutch shaft (736).
  14. Remove the tape from the clutch shaft.
    15. Fig 8: 1st Coast Clutch Assembly & 1st And 2nd Clutch Shaft
    GM1345515Courtesy of GENERAL MOTORS CORP.
  15. Install the 1st coast clutch assembly (757) onto the 1st and 2nd clutch shaft (736). Turn the clutch hub to align to the clutch discs. Ensure the hub is installed completely in the clutch discs.
    16. Fig 9: 1st And 2nd Clutch Shaft Rear Bearing
    GM1203949Courtesy of GENERAL MOTORS CORP.
  16. Install the 1st/2nd clutch shaft rear bearing (719) on the 1st/2nd clutch shaft using DT 46509  and a hydraulic press. See Special Tools .
    17. Fig 10: Measuring The Axial Clearance For The 1st Drive Gear
    GM1203942Courtesy of GENERAL MOTORS CORP.
  17. Measure the axial clearance for the 1st drive gear.
    1. Position the 1st/2nd clutch shaft assembly in a soft-jaw vise.
    2. Install the SA9179NE  and a hole attachment tool on the 1st/coast hub (752).
    3. Set the dial indicator to zero.
    4. Lift up on the 1st/coast hub (752) and record the axial clearance reading.
    5. Measure the axial clearance in 2 more locations.
    6. Average the readings to get the axial clearance.

      Specifications:  1st gear axial clearance 0.085-0.130 mm (0.003-0.05 in)

    • Replace the 1st/coast hub washer with a thicker washer to be within the axial clearance specifications.
    • If the axial clearance is still higher than the specification, disassembly the 1st/2nd clutch shaft and inspect for excessive wear on the thrust bearing surfaces of the gears. Refer to 1st/2nd Clutch Shaft in Transmission Clearance Specifications .
    • If the axial clearance is lower than the specification, inspect for burrs or contamination on the thrust bearing surfaces or the gears.
    18. Fig 11: Installing 1st/2nd Clutch Shaft Retaining Nut Washer Using DT 46509 & DT 46418
    GM1203950Courtesy of GENERAL MOTORS CORP.
  18. Using DT 46509  (1) and DT 46418  (2), install the new 1st/2nd clutch shaft retaining nut washer (720). See Special Tools . The marked side of the washer aligns up. See Special Tools .
    19. Fig 12: 1st And 2nd Clutch Shaft Retaining Nut & 26 mm
    GM1203951Courtesy of GENERAL MOTORS CORP.
  19. Install a new 26 mm, 1st and 2nd clutch shaft retaining nut (721).
  20. Hand tighten the nut to seat against the washer.
    21. Fig 13: Tightening The 1st/2nd Clutch Shaft Retainer Nut Using A Torque Wrench
    GM1358313Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  21. Use the following to tighten the 1st/2nd clutch shaft retaining nut (721):
    1. Lay the 1st/2nd clutch shaft assembly on a bench.
    2. Insert DT 46540  between the 1st/coast clutch housing (718) and the 1st/2nd clutch shaft rear bearing (719). See Special Tools .
    3. Using a torque wrench and a 38 mm six-point socket tighten the 1st/2nd clutch shaft retainer nut (721). Do not use an impact wrench.
    4. Hold the DT 46540  against the bench top. See Special Tools .

      Tighten:  Tighten the retaining nut to 178 N.m (132 lb ft)

    22. Fig 14: Staking The 1st And 2nd Clutch Shaft Retaining Nut Using A 3.5 mm Punch
    GM1203953Courtesy of GENERAL MOTORS CORP.
  22. Using a 3.5 mm (9/64 in) punch (1), stake the 1st and 2nd clutch shaft retaining nut (721)

    Specification:  Stake the 1st and 2nd clutch shaft retaining nut to 0.7-1.3 mm (0.03-0.05 in)

    23. Fig 15: 1st/2nd Clutch Shaft & Fluid Passage Seals
    GM1507166Courtesy of GENERAL MOTORS CORP.
  23. Install new 1st/2nd clutch shaft fluid passage seals (738) on the 1st/2nd clutch shaft.
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