LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1536 (Automatic Transmission - 5AT - Introduction (2 Of 2)) >> Repair Instructions >> Repair Instructions - Off Vehicle >> 1st and 2nd Clutch Shaft Disassemble

1st and 2nd Clutch Shaft Disassemble

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: Measuring The Axial Clearance For The 1st Drive Gear
    GM1203942Courtesy of GENERAL MOTORS CORP.
  1. Measure the axial clearance for the 1st drive gear. Measuring the axial clearance before disassembly of the 1st/2nd clutch shaft will help determine the wear on the components and what selective washer to use during assembly.
    1. Position the 1st/2nd clutch shaft assembly in a soft-jaw vise with the nut end up.
    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.

      Specification:  1st gear axial clearance 0.085-0.130 mm (0.003-0.050 in)

      • If the axial clearance is higher than the specification, during inspection look for excessive wear on the thrust bearing surfaces of the gears.
      • If there is not excessive wear, replace the 1st/coast hub washer (722) with a thicker washer to be within the axial clearance specifications.
      • If the axial clearance is lower than the specification, during inspection look for burrs or contamination on the thrust bearing surfaces of the gears.
    7. Record the measurement for reference during assembly.
    2. Fig 2: Removing The Stake Area From The 1st/2nd Clutch Shaft Retaining Nut Using A Chisel
    GM1353665Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure that all the metal particles are collected in order to prevent internal damage to the transaxle or bearings.
  2. Using a chisel (1) remove the stake area from the 1st/2nd clutch shaft retaining nut (721). Do not damage the threads on the clutch shaft.
    3. Fig 3: View Of 1st/2nd Clutch Shaft Retainer Nut
    GM1345869Courtesy of GENERAL MOTORS CORP.
  3. Remove the 1st/2nd clutch shaft retainer nut (721).
    1. Lay the 1st/2nd clutch shaft assembly on a bench.
    2. Insert DT 46540  between the 1st/coast housing (718) and the 1st/2nd clutch shaft rear bearing (719). See Special Tools .
    3. Using a breaker bar and a 38 mm six-point socket loosen the 1st/2nd clutch shaft retainer nut (721).
    4. Hold the DT 46540  against the bench top. See Special Tools .
    5. Remove the 1st/2nd clutch shaft retainer nut (721).
    6. Remove any burrs or metal shavings from the clutch shaft threads.
    4. Fig 4: Removing The 1st/2nd Clutch Shaft Rear Bearing & the 1st/2nd Clutch Drive Gear Using A Hydraulic Press
    GM1203938Courtesy of GENERAL MOTORS CORP.
    NOTE: Support the component while using the press. Failure to support the component may allow the component to drop, causing damage.
  4. Using a hydraulic press remove the 1st/2nd clutch shaft rear bearing (719) and the 1st/2nd clutch drive gear (730).
    • Use press plates (1) under the 1st/2nd clutch shaft drive gear (730).
    • Protect the threads of the clutch shaft using a shaft protector (2).
    • Hold onto the 1st/2nd clutch shaft assembly to prevent the assembly from dropping.
    5. Fig 5: Rear Bearing, Drive Gear & Components Removed
    GM1470590Courtesy of GENERAL MOTORS CORP.
  5. Separate the following components, which were removed when pressing off the rear bearing and drive gear.
    • 1st/2nd clutch shaft retaining nut washer (720)
    • 1st/2nd clutch shaft rear bearing (719)
    • 1st/coast clutch assembly (757)
    • 1st/coast clutch hub thrust bearing race (722)
    • 1st/coast clutch hub thrust bearing (723)
    • 1st/coast clutch hub and coast sprag assembly (752)
    • 1st drive gear thrust bearing (727)
    • 1st drive gear inner bearing (728)
    • 1st drive gear inner bearing race (729)
    • 1st drive gear thrust bearing (727)
    • 1st/2nd clutch shaft drive gear (730)
    6. Fig 6: Exploded View Of 1st/2nd Clutch Shaft & Components
    GM1679630Courtesy of GENERAL MOTORS CORP.
  6. Remove the 2nd clutch housing retaining ring (751).
  7. Remove the following from the 1st/2nd clutch shaft (736):
    • The 2nd clutch housing assembly (749)
    • The splined washer (734)
    • The 2nd drive gear thrust bearing (731)
    • The 2nd drive with clutch hub and park gear (732)
    • The 2nd drive gear inner bearing (733)
    • The 2nd drive gear thrust bearing (731)
    8. Fig 7: Exploded View Of 1st and 2nd Clutch Shaft
    GM1679633Courtesy of GENERAL MOTORS CORP.
  8. Remove the 1st/coast clutch housing fluid passage seals (735).
  9. Remove the 1st/2nd clutch shaft fluid passage seals (738).
  10. Remove the 2nd clutch housing fluid passage seals (737).
    11. Fig 8: 1st and 2nd Clutch Shaft Inspection Areas
    GM1679646Courtesy of GENERAL MOTORS CORP.
  11. Clean the 1st/2nd clutch shaft (736) in solvent, air dray and blow out the oil passages.
  12. Inspect the 1st/2nd clutch shaft (736) for the following conditions:

    Refer to 1st/2nd Clutch Shaft in Transmission Clearance Specifications .

    • Shaft splines for excessive wear, witness marks from the gears is normal
    • Bearing journal surfaces for wear, scoring, or brinelling
    • Fluid passage seal grooves for damage
    • Thrust bearing surface on shaft flange for excessive wear, roughness, or scoring
  13. Replace the 1st/2nd clutch shaft (736) if faulty.
  14. Clean the gears and bearing for the 1st/2nd clutch shaft insolvent and air dry.
  15. Inspect the gears for damaged teeth.
  16. Inspect the thrust surface on the gears for excessive wear and scoring.
  17. Inspect the bearings for roughness, brinelling, or bent cages.
  18. Replace any faulty components.
    19. Fig 9: Inspecting The Operation Of 1st/Coast Hub & Coast Sprag Assembly
    GM1203945Courtesy of GENERAL MOTORS CORP.
  19. Inspect the operation of the 1st/coast hub and coast sprag assembly (752).
    • Hold the coast clutch hub (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.
  20. Inspect the gears on the 1st/coast hub and coast sprag assembly (752) for damage or excessive wear.
  21. Replace the 1st/coast hub and coast sprag assembly (752) if faulty. The one-way clutch and the hub are serviced as an assembly.
    22. Fig 10: Coast Sprag Assembly, Coast Clutch Hub & 1st Drive Gear
    GM1203946Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If necessary the 1st/coast hub and coast sprag assembly (752) can be disassembled for cleaning.
  22. Using EN 46342  (1) and DT 46516  (2) with a hydraulic press, remove the coast clutch hub (724) form the 1st drive gear (726). See Special Tools .
  23. Clean the components in solvent and air dry.
scientia non olet · About LEMON Manuals