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Home >> Chevrolet >> 2008 >> Optra5 LT, Automatic >> Repair and Diagnosis >> Transmission >> Hydraulic Diagrams >> Automatic Transaxle - AISIN 81-40LE - Service, Overhaul, Removal & Installation & Diagnosis >> Transmission Assemble >> Assembly Procedure

Assembly Procedure

    Fig 1: View Of Transaxle Rear Cover, Screw Plugs And 4 O-Rings
    GM1245944Courtesy of GENERAL MOTORS CORP.
  1. Install 4 new O-rings to the 4 screw plugs.
    2. NOTE: Refer to Fastener Notice .
  2. Install the 4 screw plugs with the O-rings to the transaxle rear cover.

    Tighten:  Tighten the screw plugs to 7.4 N.m (65 lb in)  .

    3. Fig 2: View Of Transaxle Rear Cover And Seal Rings
    GM1245946Courtesy of GENERAL MOTORS CORP.
  3. Install the 2 seal rings to the transaxle rear cover.
    4. Fig 3: Measuring Free Length Of O/D Brake Piston Return Spring
    GM1245948Courtesy of GENERAL MOTORS CORP.
  4. Using the vernier calipers, measure the free length of the overdrive (O/D) brake piston return spring together with the spring seat.

    Specification:  The standard free length is 18.99 mm (0.7476 in).

    5. Fig 4: View Of O/D Brake Piston And O-Rings
    GM1245947Courtesy of GENERAL MOTORS CORP.
  5. Coat 2 new O-rings (1) with automatic transaxle fluid (ATF), install them to the O/D brake piston.
    6. Fig 5: View Of O/D Brake Piston And O-Rings
    GM1245950Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Be careful not to damage the O-rings of the O/D brake piston.
  6. Coat the O/D brake piston with ATF, install it to the transaxle rear cover.
    7. Fig 6: View Of Driver, DT 46451 And DT46454
    GM1245936Courtesy of GENERAL MOTORS CORP.
    NOTE: In order to prevent damage to the brake piston, do not depress the brake piston lower than 1-2 mm (0.039-0.078 in) beyond the snap ring groove.
  7. Using the DT 46451  (1), DT 46454  (2) and a driver, install the O/D brake return spring and snap ring to the transaxle rear cover. See Special Tools .
    8. Fig 7: Installing Side Bearing Outer Race And Transaxle Housing Using DT 46462 And DT 46465
    GM1245951Courtesy of GENERAL MOTORS CORP.
  8. Using the DT 46462  (2), DT 46465  (1), install a new side bearing outer race into the transaxle housing. See Special Tools .
    9. Fig 8: Driving In A Transaxle Housing Oil Seal
    GM1245952Courtesy of GENERAL MOTORS CORP.
  9. Using the DT 46471  (1) and a hammer, drive in a new transaxle housing oil seal. See Special Tools .

    Specification:  The oil seal in depth is 3.1 mm (0.122 in).

    10. Fig 9: Identifying Oil Seal And Transaxle Housing
    GM1245931Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Press-fit the outer tapered roller bearing race until it contacts the transaxle housing.
  10. Install a new outer tapered roller bearing race into the transaxle housing.
    11. Fig 10: View Of No. 1 Transaxle Apply Pipe Clamp
    GM1245940Courtesy of GENERAL MOTORS CORP.
  11. Install the transaxle lube apply pipe and differential gear lube apply pipe to the transaxle housing.
  12. Install the No. 1 transaxle apply pipe clamp to the transaxle housing with the bolt.

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in)  .

    13. Fig 11: View Of Oil Reservoir Lock Plate And Bolts
    GM1245935Courtesy of GENERAL MOTORS CORP.
  13. Install the oil reservoir lock plate to the transaxle housing with the 3 bolts.

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in)  .

    14. Fig 12: Identifying Counter Driven Gear Outer Tapered Roller Bearing Race And Shim
    GM1245930Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: First install a shim of the same thickness as before.
  14. Install the shim to the transaxle case.
  15. Install a new bearing outer race into the transaxle case.
    16. Fig 13: Driving In Transaxle Case Oil Seal
    GM1245949Courtesy of GENERAL MOTORS CORP.
  16. Using the DT 47521  (1) and a hammer, drive in a new transaxle case oil seal. See Special Tools .

    Specifications:  The oil seal in depth is 4.3 mm (0.169 in).

    17. IMPORTANT: First install a shim of the same thickness as before.
  17. Install the shim to the transaxle case.
    18. Fig 14: Pressing In Outer Tapered Roller Bearing Race
    GM1245954Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Press-fit the shim until it contacts the transaxle case.
  18. Using the DT 46464  (2) and DT 46465  (1), press in a new outer tapered roller bearing race into the transaxle case. See Special Tools .
    19. Fig 15: Identifying No. 1 Transaxle Case Plate
    GM1245953Courtesy of GENERAL MOTORS CORP.
  19. Install the No. 1 transaxle case plate to the transaxle case with the bolt.

    Tighten:  Tighten the bolt to 9.8 N.m (87 lb in)  .

    20. Fig 16: View Of Differential Gear And Transaxle Case
    GM1245956Courtesy of GENERAL MOTORS CORP.
  20. Install the differential gear to the transaxle case.
    21. Fig 17: View Of Transaxle Housing
    GM1245958Courtesy of GENERAL MOTORS CORP.
  21. Install the transaxle housing and tighten the 16 bolts of the transaxle housing temporarily.
  22. Tighten 8 or 9 bolts out of the 16 bolts of the transaxle housing completely.

    Tighten:  Tighten the bolt to 29 N.m (22 lb ft)  .

    23. Fig 18: Turning Differential Gear Assembly
    GM1245959Courtesy of GENERAL MOTORS CORP.
  23. Using the DT 46461  , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle. See Special Tools .
    24. Fig 19: Measuring Preload Of Differential Gear
    GM1245955Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Note down the measured valve.
  24. Using the DT 46461  and a small torque wrench, measure the preload of the differential gear. See Special Tools .
    25. Fig 20: View Of Counter Driven Gear
    GM1245960Courtesy of GENERAL MOTORS CORP.
  25. Remove the transaxle housing and install the counter driven gear.
    26. Fig 21: View Of Transaxle Housing
    GM1245958Courtesy of GENERAL MOTORS CORP.
  26. Install the transaxle housing and tighten the 16 bolts of the transaxle housing temporarily.
  27. Tighten the bolts of the transaxle housing in the same manner as in step 22.

    Tighten:  Tighten the bolts to 29 N.m (22 lb in)  .

    28. Fig 22: Turning Differential Gear Assembly
    GM1245959Courtesy of GENERAL MOTORS CORP.
  28. Using a DT 46461  , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle. See Special Tools .
    29. Fig 23: Measuring Preload Of Differential Gear
    GM1245955Courtesy of GENERAL MOTORS CORP.
  29. Using a DT 46461  and a small torque wrench, measure the preload of the differential gear. See Special Tools . From this valve deduct the valve measured in step 24. This is the preload of the counter driven gear.

    Specification: 

    • The preload for a new bearing is 0.33-0.76 N.m (3.21-6.77 lb in).
    • The preload for a used bearing is 0.17-0.38 N.m (1.48-3.39 lb in).

    30. Fig 24: Measuring Free Length Of 1st And Reverse Brake Piston Return Spring
    GM1245963Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When the preload is larger than the specification, select a thinner adjuster shim. When the preload is smaller than specification, select a thicker adjuster shim.
    If the preload of the counter driven gear does not satisfy the specification, select the adjuster shim from the table below and re-measure the valve. Until the valve is within the specification, repeat the procedure.
  30. Using the vernier calipers, measure the free length of the 1st and reverse brake piston return spring together with the spring seat.

    Specification:  The standard free length is 18.053 mm (0.71075 in).

    31. Fig 25: View Of Disc Sliding Surface
    GM1245961Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
    IMPORTANT: Before assembling the new discs, soak them in ATF for at least 15 minutes.
  31. Check to see if the sliding surface of the disc, plate and the flange of the 1st and reverse brake are worn or burnt. Replace them, if necessary.
    32. Fig 26: View Of 1st And Reverse Brake Piston O-Rings
    GM1245934Courtesy of GENERAL MOTORS CORP.
  32. Coat 2 new O-rings (1) with ATF, install them to the 1st and reverse piston.
    33. Fig 27: View Of 1st And Reverse Brake Piston
    GM1375541Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Be careful not to damage the O-rings of the 1st and reverse brake piston.
  33. Install the 1st and reverse brake piston to the transaxle case.
    34. Fig 28: View Of Return Springs And Transaxle Case
    GM1245964Courtesy of GENERAL MOTORS CORP.
  34. Install the return spring to the transaxle case.
    35. Fig 29: View Of Plates, Discs And Flange
    GM1245965Courtesy of GENERAL MOTORS CORP.
  35. Install the 4 plates, 4 discs and flange.
  36. Install in order: 2-1-2-1-2-1-2-1-3, 3=Plate, 1=Disc, 2=Flange.
    37. Fig 30: Identifying DT 46455, DT 46457, 1st And Reverse Brake Snap Ring
    GM1245938Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure that the snap ring is installed in the groove of the transaxle case correctly.
  37. Using the DT 46457  (2) and DT 46455  (1) install the snap ring. See Special Tools .
    38. Fig 31: Measuring 1st & Reverse Brake Piston Stroke Using A Dial Indicator
    GM1245966Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the piston stroke is non-standard, inspect the discs, plates and flange. The piston stroke is 0.6-1.3 mm (0.024-0.051 in).
  38. Using a dial indicator, measure the 1st and reverse brake piston stroke while applying and releasing 392-785 kPa (57-114 psi)  of compressed air through port (1).
    39. Fig 32: View Of DT 46460, DT 46455 And DT 46456
    GM1245967Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Be careful not to apply excessive force to the transaxle case.
  39. Using the DT 46460  (3), DT 46455  (2) and DT 46456  (1), install the counter drive gear. See Special Tools .
  40. Coat a new oil seal with ATF.
    41. Fig 33: Identifying Oil Seal Depth
    GM1245968Courtesy of GENERAL MOTORS CORP.
  41. Install the oil seal to the transaxle case.

    Specification:  The oil seal in depth (a) is 0.75-1.25 mm (0.3802-0.3998 in).

    42. Fig 34: View Of Parking Lock Rod And Manual Valve Lever
    GM1245921Courtesy of GENERAL MOTORS CORP.
  42. Install the parking lock rod to the manual valve lever.
    43. Fig 35: View Of Manual Valve Lever And Spacer
    GM1245969Courtesy of GENERAL MOTORS CORP.
  43. Install a new spacer to the manual valve lever.
    44. Fig 36: View Of Manual Valve Lever And Shaft
    GM1245970Courtesy of GENERAL MOTORS CORP.
  44. Install the manual valve lever shaft and manual valve lever.
    45. Fig 37: Driving Pin Using A Pin Punch And Hammer
    GM1245919Courtesy of GENERAL MOTORS CORP.
  45. Using a pin punch and hammer, drive in a new pin.
    46. Fig 38: Staking Spacer Through Small Hole
    GM1245971Courtesy of GENERAL MOTORS CORP.
  46. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
  47. Using a pin punch, stake the spacer through the small hole.
  48. Check that the spacer does not turn.
    49. Fig 39: View Of Bolt And Manual Detent Spring
    GM1245917Courtesy of GENERAL MOTORS CORP.
  49. Install the manual detent spring with the bolt.

    Tighten:  Tighten the bolts to 9.8 N.m (87 lb in)  .

    50. Fig 40: View Of Parking Lock Pawl, Shaft And Torsion Spring
    GM1245916Courtesy of GENERAL MOTORS CORP.
  50. Install the parking lock shaft, torsion spring and parking lock pawl.
    51. Fig 41: View Of Edge Of Torsion Spring
    GM1245972Courtesy of GENERAL MOTORS CORP.
  51. Check that the edge of the torsion spring fits into the groove securely.
    52. Fig 42: View Of Parking Lock Pawl Bracket And Bolts
    GM1245915Courtesy of GENERAL MOTORS CORP.
  52. Install the parking lock pawl bracket with the 2 bolts.

    Tighten:  Tighten the bolts to 7.4 N.m (65 lb in)  .

    53. Fig 43: View Of DT 46460, DT 46455 And Planetary Ring Gear
    GM1245973Courtesy of GENERAL MOTORS CORP.
  53. Using the DT 46460  (2) and the DT 46455  (1), install the planetary ring gear. See Special Tools .
  54. Before installing the planetary ring gear, be sure to replace the planetary ring flange of the planetary ring gear with a new one.
    55. Fig 44: View Of Counter Drive Gear And Parking Lock Pawl
    GM1245914Courtesy of GENERAL MOTORS CORP.
  55. Fix the counter drive gear with the parking lock pawl.
    56. Fig 45: Removing Planetary Ring Gear Nut Using DT 46472
    GM1245906Courtesy of GENERAL MOTORS CORP.
  56. Using the DT 46472  (1), install a new nut. See Special Tools .

    Tighten:  Tighten the nut to 9.8 N.m (87 lb in)  .

    57. Fig 46: Turning Counter Drive Gear Using A Wrench
    GM1245975Courtesy of GENERAL MOTORS CORP.
  57. Using a small torque wrench, while turning to counter drive gear 100 turn per minute and measure the preload.

    Tighten:  Tighten the nut to 29 N.m (22 lb ft)  or less.

    Specification:  When the preload is smaller than the specification, tighten the nut more and adjust the preload to 0.05-0.35 N.m (0.43-3.12 lb in)  .

  58. Stake the nut.
    59. Fig 47: View Of Planetary Gear And Transaxle Case
    GM1245974Courtesy of GENERAL MOTORS CORP.
  59. Install the planetary gear to the transaxle case.
    60. Fig 48: View Of Planetary Carrier Thrust Washer And Planetary Gear
    GM1245976Courtesy of GENERAL MOTORS CORP.
  60. Coat the planetary carrier thrust washer with petroleum jelly and install it onto the planetary gear.
    61. Fig 49: View Of No. 2 One-Way Clutch And Transaxle Case
    GM1245977Courtesy of GENERAL MOTORS CORP.
  61. Install the No. 2 one-way clutch to the transaxle case.
    62. Fig 50: Verifying Planetary Gear Turns Freely
    GM1245979Courtesy of GENERAL MOTORS CORP.
  62. Check that the planetary gear turns freely counterclockwise and locks clockwise.
    63. Fig 51: Identifying Anti-Rattle Clip
    GM1245980Courtesy of GENERAL MOTORS CORP.
  63. Install the anti-rattle clip in the place shown in the illustration (the space between the No. 2 one-way clutch outer race and transaxle case), push the anti-rattle clip in until you hear the click.
    64. Fig 52: Measuring Free Length Of 2nd Brake Piston Return Spring
    GM1245978Courtesy of GENERAL MOTORS CORP.
  64. Using vernier calipers, measure the free length of the 2nd brake piston return spring together with the spring seat.

    Specification:  The standard free length is 15.85 mm (0.6240 in).

    65. Fig 53: View Of Disc
    GM1245981Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
    IMPORTANT: Before assembling the new discs, soak them in ATF for at least 15 minutes.
  65. Check to see if the sliding surface of the disc, plate and flange of 2nd brake are worn or burnt. Replace them, if necessary.
    66. Fig 54: Identifying Flange, Discs And Plates
    GM1245983Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure the snap ring is installed in the groove of the transaxle case correctly.
  66. Install the flange, 2 discs and 2 plates.
  67. Install in this order 2-1-3-1-3, 1=Disc, 3=Plate, 2=Flange.
  68. Install the 2nd brake return spring.
    69. Fig 55: Identifying 2nd Brake Piston O-Rings
    GM1245910Courtesy of GENERAL MOTORS CORP.
  69. Coat 2 new O-rings (1) with ATF, install them to the 2nd brake piston.
    70. Fig 56: View Of 2nd Brake Piston & 2nd Brake Clutch Cylinder
    GM1245984Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Be careful not to damage the O-rings.
  70. Install the 2nd brake piston into the 2nd brake clutch cylinder.
    71. Fig 57: View Of 2nd Brake Clutch Cylinder And Transaxle Case
    GM1245982Courtesy of GENERAL MOTORS CORP.
  71. Install the 2nd brake clutch cylinder to the transaxle case.
    72. Fig 58: Identifying DT 46455 And DT 46458
    GM1245908Courtesy of GENERAL MOTORS CORP.
  72. Using the DT 46455  (1) and DT 46458  (2), compress the 2nd brake piston return spring. See Special Tools .
    73. IMPORTANT: Make sure that the snap ring is installed in the groove of the transaxle case correctly.
  73. Using the screwdriver, install the snap ring.
    74. Fig 59: Identifying Thrust Bearing Race And Front Planetary Sun Gear
    GM1245985Courtesy of GENERAL MOTORS CORP.
  74. Coat the thrust bearing race with petroleum jelly and install it onto the front planetary sun gear.

    Specification: 

    • The race inner diameter is 19.3 mm (0.760 in).
    • The race outer diameter is 29.0 mm (1.142 in).

    75. Fig 60: Identifying Front Planetary Sun Gear And Thrust Bearing Race
    GM1245907Courtesy of GENERAL MOTORS CORP.
  75. Install the front planetary sun gear to the transaxle case.
    76. Fig 61: View Of 1-Way Clutch Assembly, Thrust Washer And Rear Planetary Sun Gear
    GM1245904Courtesy of GENERAL MOTORS CORP.
  76. Install the thrust washer and one-way clutch assembly to the rear planetary sun gear.
    77. Fig 62: Identifying Thrust Bearing Race And Rear Planetary Sun Gear
    GM1245986Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Check the direction of the bearing.
  77. Coat the thrust bearing race with petroleum jelly and install it onto the rear planetary sun gear and one-way clutch assembly.

    Specification: 

    • The bearing inner diameter 42.5 mm (1.673 in).
    • The bearing outer diameter 57.5 mm (2.264 in).

    78. Fig 63: View Of Rear Planetary Sun Gear And 1-Way Clutch Assembly
    GM1245900Courtesy of GENERAL MOTORS CORP.
  78. Install the rear planetary sun gear and one-way clutch assembly to the transaxle case.
    79. Fig 64: View Of Thrust Bearing Race And Transaxle Case
    GM1245987Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Check the direction of the race.
  79. Coat the thrust bearing race with petroleum jelly and install it onto the transaxle case.

    Specification: 

    • The race inner diameter is 34.95 mm (1.3760 in).
    • The race outer diameter is 45.50 mm (1.7913 in).

    80. Fig 65: View Of Thrust Needle Roller Bearing And Forward Clutch Hub
    GM1245988Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Check the direction of the bearing.
  80. Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward clutch hub.

    Specification: 

    • The bearing inner diameter is 33.3 mm (1.311 in).
    • The bearing outer diameter is 46.5 mm (1.831 in).

    81. Fig 66: View Of Forward Clutch Hub And Transaxle Case
    GM1245886Courtesy of GENERAL MOTORS CORP.
  81. Install the forward clutch hub to the transaxle case.
    82. Fig 67: View Of Thrust Bearing Race And Forward Clutch Hub
    GM1245990Courtesy of GENERAL MOTORS CORP.
  82. Coat the thrust bearing race with petroleum jelly and install it onto the forward clutch hub.

    Specification: 

    • The race inner diameter is 19.3 mm (1.760 in).
    • The race outer diameter is 30.6 mm (1.205 in).

    83. Fig 68: Identifying Thrust Needle Roller Bearing, Race And Forward/Reverse Clutch Assembly
    GM1245888Courtesy of GENERAL MOTORS CORP.
  83. Install the thrust bearing race and thrust needle roller bearing to the forward and reverse clutch assembly.

    Specification: 

    • The race inner diameter is 18.1 mm (0.713 in).
    • The race outer diameter is 28.2 mm (1.110 in).
    • The bearing inner diameter is 18.1 mm (0.713 in).
    • The bearing outer diameter is 29.6 mm (1.165 in).

    84. Fig 69: View Of Forward/Reverse Clutch Assembly And Transaxle Case
    GM1245989Courtesy of GENERAL MOTORS CORP.
  84. Install the forward and reverse clutch assembly to the transaxle case.
    85. Fig 70: View Of Disc
    GM1245961Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the lining of the disc is peeling off or discolored, or even if the part of the printed mark is defaced, replace all discs.
    IMPORTANT: Before assembling new discs, soak them in ATF for at least 15 minutes.
  85. Check to see if the sliding surface of the disc, plate and flange of 2nd coast and O/D brake are worn or burnt. Replace them, if necessary.
    86. Fig 71: Installing Snap Ring To Transaxle Case Using A Screwdriver
    GM1245991Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure that the snap ring is installed in the groove of the transaxle case correctly.
  86. Using a screwdriver, install the snap ring to the transaxle case.
    87. Fig 72: Identifying O/D Brake Flange, Discs And Plates
    GM1245889Courtesy of GENERAL MOTORS CORP.
  87. Install the flange, 2 discs and 2 plates to the transaxle case.
  88. Install in the following order: 3-2-3-2-1, 3=Plate, 2=-Disc, 1=Flange.
  89. Clean the connected part the transaxle case and transaxle rear cover.
    90. Fig 73: Measuring Distance Between 2nd Coast And O/D Brake Flange
    GM1245992Courtesy of GENERAL MOTORS CORP.
  90. As shown in the illustration, place a straight edge on the transaxle case and measure the distance between the 2nd coast and O/D brake flange and straight edge using vernier calipers (a).
    91. Fig 74: Measuring Distance Between Transaxle Rear Cover And Straight Edge
    GM1245994Courtesy of GENERAL MOTORS CORP.
  91. As shown in the illustration, place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and the straight edge using vernier calipers (a).
  92. Calculate the piston stroke value using the following formula. Select a flange which satisfies the piston stroke value and install it.
    93. Fig 75: Identifying Apply Gaskets
    GM1245893Courtesy of GENERAL MOTORS CORP.
  93. Install 4 new apply gaskets to the transaxle rear cover.
    94. Fig 76: View Of Thrust Needle Roller Bearing And Forward/Reverse Clutch Assembly
    GM1245993Courtesy of GENERAL MOTORS CORP.
  94. Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward and reverse clutch assembly.

    Specification: 

    • The bearing inner diameter is 43.2 mm (1.701 in).
    • The bearing outer diameter is 62.0 mm (2.441 in).

  95. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle rear cover or transaxle case.
    96. Fig 77: View Of Transaxle Without Rear Cover
    GM1245996Courtesy of GENERAL MOTORS CORP.
  96. Apply formed in place gasket (FIPG) to the transaxle rear cover.

    Specification:  The FIPG three bond 1281, or equivalent, seal bend width is 1.2 mm (0.047 in).

    97. Fig 78: View Of Transaxle Rear Cover, Transaxle Case And Bolts
    GM1245995Courtesy of GENERAL MOTORS CORP.
  97. Install the transaxle rear cover to the transaxle case with the 9 bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft)  .

    98. Fig 79: View Of Counter Driven Gear Assembly And Transaxle Case
    GM1245890Courtesy of GENERAL MOTORS CORP.
  98. Install the counter driven gear assembly to the transaxle case.
    99. Fig 80: View Of Differential Gear Assembly And Transaxle Case
    GM1245884Courtesy of GENERAL MOTORS CORP.
  99. Install the differential gear assembly to the transaxle case.
    100. Fig 81: Identifying Direct Clutch Hub And Transaxle Case
    GM1245998Courtesy of GENERAL MOTORS CORP.
  100. Install the direct clutch hub to the transaxle case.
    101. Fig 82: View Of Thrust Bearing Race, Thrust Needle Roller Bearing And Transaxle Case
    GM1245997Courtesy of GENERAL MOTORS CORP.
  101. Install the thrust bearing race and thrust needle roller bearing to the transaxle case.

    Specification: 

    • The race inner diameter is 20.5 mm (0.807 in).
    • The race outer diameter is 32.6 mm (1.283 in).
    • The bearing inner diameter is 17.8 mm (0.701 in).
    • The bearing outer diameter is 30.2 mm (1.189 in).

    102. Fig 83: View Of Direct Clutch Assembly And Transaxle Case
    GM1245897Courtesy of GENERAL MOTORS CORP.
  102. Install the clutch assembly to the transaxle case.
    103. Fig 84: View Of Apply Gasket
    GM1245899Courtesy of GENERAL MOTORS CORP.
  103. Install the new apply gasket.
    104. IMPORTANT: Check the direction of the bearing.
  104. Install the thrust needle roller bearing to the transaxle case.
    105. Fig 85: View Of Oil Pump And Input Shaft
    GM1246000Courtesy of GENERAL MOTORS CORP.
  105. Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transaxle case.
    106. Fig 86: View Of Oil Pump And Bolts
    GM1245881Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  106. Install the 6 oil pump bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft)  .

    107. Fig 87: Measuring Input Shaft End Play
    GM1245882Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the end play is not as specified, select and replace the thrust needle roller bearing.
  107. Measure the end play in axial direction.

    Specification: 

    • The end play is 0.3-0.9 mm (0.012-0.035 in).
    • The bearing inner diameter is 32.5 mm (1.280 in).
    • The bearing outer diameter is 48.5 mm (1.909 in).
    • The bearing thickness is 4.21 mm (0.1657 in).
    • The bearing inner diameter is 32.9 mm (1.295 in).
    • The bearing outer diameter is 48.5 mm (1.909 in).
    • The bearing thickness is 3.62 mm (0.1425 in).

    108. Fig 88: Confirming Input Shaft Rotates Smoothly
    GM1245999Courtesy of GENERAL MOTORS CORP.
  108. Make sure that the input shaft rotates smoothly.
    109. Fig 89: View Of FIPG And Transaxle Housing
    GM1246001Courtesy of GENERAL MOTORS CORP.
  109. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle housing or transaxle case.
  110. Apply formed in place gasket (FIPG) to the transaxle housing.

    Specification:  FIPG: Three bond 1281 or equivalent, seal bend width is 1.2 mm (0.047 in).

    111. Fig 90: View Of Transaxle Housing, Transaxle Case And Bolts
    GM1246002Courtesy of GENERAL MOTORS CORP.
  111. Install the transaxle housing to the transaxle case with the 16 bolts.

    Tighten:  Tighten the bolts to 29 N.m (22 lb ft)  .

  112. Apply seal packing or equivalent to the bolts.
    113. Fig 91: View Of Transaxle Wire And O-Ring
    GM1245876Courtesy of GENERAL MOTORS CORP.
  113. Coat a new O-ring (1) with ATF, install it to the transaxle wire.
    114. Fig 92: View Of Transaxle Wire And Bolt
    GM1245877Courtesy of GENERAL MOTORS CORP.
  114. Install the transaxle wire to the transaxle case with the bolt.

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in)  .

    115. Fig 93: View Of Springs, Pistons And O-Rings
    GM1246003Courtesy of GENERAL MOTORS CORP.
  115. Coat new 6 O-rings with ATF and install them to the pistons (1, 2, 3).
  116. Coat the 3 springs and 3 accumulator pistons with ATF, install them to the holes.
    117. Fig 94: Identifying Apply Gasket
    GM1245857Courtesy of GENERAL MOTORS CORP.
  117. Coat a new apply gasket with ATF, install it to the transaxle case.
    118. Fig 95: Identifying Brake Drum Gasket
    GM1245885Courtesy of GENERAL MOTORS CORP.
  118. Coat a new brake drum gasket with ATF, install it to the transaxle case.
    119. Fig 96: View Of Check Valve And Spring
    GM1245870Courtesy of GENERAL MOTORS CORP.
  119. Install the spring and check valve.
    120. Fig 97: View Of Manual Valve Control Rod And Lever
    GM1246004Courtesy of GENERAL MOTORS CORP.
  120. Connect the manual valve control rod to the manual valve lever as shown in the illustration.
    121. Fig 98: Identifying Valve Body Assembly And Bolts
    GM1245868Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When installing the valve body to the transaxle case, do not let each of the accumulator pistons incline. When installing the valve body to the transaxle case, do not hold the solenoids.
  121. Install the valve body assembly to the transaxle case.

    Tighten:  Tighten the bolts to 11 N.m (97 lb in)  .

    122. Fig 99: Identifying Solenoid Connectors
    GM1245869Courtesy of GENERAL MOTORS CORP.
  122. Connect the transaxle wire connector and harness to the valve body assembly.
  123. Connect the 5 connectors.
    1. Lock-up control solenoid (5)
    2. Pressure control solenoid (1)
    3. No. 2 shift solenoid (2)
    4. No. 1 shift solenoid (3)
    5. Timing solenoid (4)
    124. IMPORTANT: Make sure that the transaxle wire does not come out from the oil pan installations surface.
  124. Install the TFT sensor with clamp.
    125. Fig 100: View Of Oil Strainer Gasket
    GM1245867Courtesy of GENERAL MOTORS CORP.
  125. Install a new gasket to the oil strainer.
    126. Fig 101: View Of Oil Strainer And Bolts
    GM1245866Courtesy of GENERAL MOTORS CORP.
  126. Install the oil strainer to the valve body with the 3 bolts.

    Tighten:  Tighten the bolts to 9.8 N.m (87 lb in)  .

    127. Fig 102: View Of Oil Pan Magnets
    GM1246005Courtesy of GENERAL MOTORS CORP.
  127. Install the 2 magnets in the oil pan.
    128. Fig 103: View Of Oil Pan And Gasket
    GM1245862Courtesy of GENERAL MOTORS CORP.
  128. Install a new gasket to the oil pan and install it to the transaxle case with the 18 bolts.

    Tighten:  Tighten the bolts to 7 N.m (62 lb in)  .

    129. Fig 104: Identifying OSS Sensor And Bolts
    GM1245864Courtesy of GENERAL MOTORS CORP.
  129. Install the output shaft speed (OSS) sensor.

    Tighten:  Tighten the bolt to 7.4 N.m (65 lb in)  .

    130. Fig 105: Identifying ISS Sensor And Bolts
    GM1245863Courtesy of GENERAL MOTORS CORP.
  130. Install the No. 1 breather plug.
  131. Install the input shaft speed (ISS) sensor with the bolt.

    Tighten:  Tighten the bolts to the 5.4 N.m (48 lb in)  .

    132. Fig 106: View Of Screw Plug, O-Ring And Transaxle Case
    GM1245865Courtesy of GENERAL MOTORS CORP.
  132. Coat the new O-ring the ATF, install it to the screw plug.
  133. Install the screw plug to the transaxle case.

    Tighten:  Tighten the bolts to 7.4 N.m (65 lb in)  .

    134. Fig 107: View Of Unions, O-Rings And Transaxle Case
    GM1245859Courtesy of GENERAL MOTORS CORP.
  134. Coat the 2 new O-rings with ATF, install them to the unions.
  135. Install the 2 unions to the transaxle case.

    Tighten:  Tighten the unions to 25 N.m (18 lb ft)  .

    136. Fig 108: Identifying PNP Switch And Manual Valve Lever Shaft
    GM1245824Courtesy of GENERAL MOTORS CORP.
  136. Install the PNP switch to the manual valve lever shaft and temporarily install the 2 adjusting bolts.
  137. Install a new lock washer and nuts.

    Tighten:  Tighten the nuts to 12 N.m (106 lb in)  .

    138. Fig 109: View Of Control Lever
    GM1246006Courtesy of GENERAL MOTORS CORP.
  138. Temporarily install the control lever.
    139. Fig 110: View Of PNP Switch Lever
    GM1245822Courtesy of GENERAL MOTORS CORP.
  139. Turn the lever counterclockwise until it stops, turn it clockwise 2 notches.
  140. Remove the control lever.
    141. Fig 111: Aligning Groove With Neutral Basic Line
    GM1245808Courtesy of GENERAL MOTORS CORP.
  141. Align the groove with the neutral basic line.
  142. Tighten the 2 bolts.

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in)  .

    143. Fig 112: Staking The Nut With Lock Washer Using A Screwdriver
    GM1245810Courtesy of GENERAL MOTORS CORP.
  143. Using a screwdriver, stake the nut with the lock washer.
    144. Fig 113: View Of PNP Switch Control Lever, Washer And Nut
    GM1245825Courtesy of GENERAL MOTORS CORP.
  144. Install the control lever, washer and nut.

    Tighten:  Tighten the nut to 12 N.m (106 lb in)  .

    145. Fig 114: Identifying Torque Converter Installation Depth
    GM1246008Courtesy of GENERAL MOTORS CORP.
  145. Install the torque converter (2) to the transaxle.
  146. Measure the installation depth of the torque converter.

    Specification:  The standard value is 11.1 mm (0.44 in).

  147. If the measured value is beyond the standard value, readjust the torque converter within the specified value.
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