3rd Clutch Shaft Assemble

Tools Required

• DT 46509  Tube Style Driver. See Special Tools .
• SA9179NE  Dial Indicator

Fig 1: 3rd Clutch Housing Fluid Passage O-Ring Seals & 3rd Clutch Shaft
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The 3rd clutch shaft fluid passage seals (824) are installed after the installed height measurement.
1. Wrap the 3rd clutch shaft (823) splines with tape.
2. Install 2 new 26.7 x 1.9 mm 3rd clutch housing fluid passage O-ring seals (822) in the 3rd clutch O-ring grooves.
3. Remove the tape from the 3rd clutch shaft (823).
Fig 2: 3rd Clutch Assembly & Components Removed
Courtesy of GENERAL MOTORS CORP.
4. Install the 3rd clutch assembly (831) on the 3rd clutch shaft (823).
5. Install the 53 mm 3rd drive gear and clutch hub bearing race (800).
6. Install the 3rd drive gear and clutch hub 30 x 52 x 3 mm thrust bearing (801).
7. Install the 3rd drive gear and clutch hub 30 x 36 x 3 mm inner bearing (802).
8. Install the 3rd drive gear and clutch hub (803).
9. Install the 3rd driven gear and clutch hub 30 x 52 x 3 mm thrust bearing (801).
10. Place the 3rd driven gear (805) on the 3rd clutch shaft (823) with the hub protrusion facing down as shown and align the splines.
Fig 3: Installing 3rd Driven Gear Using DT 46509 And A Hydraulic Press
Courtesy of GENERAL MOTORS CORP.
11. Using DT 46509  and a hydraulic press, Install the 3rd driven gear (805) until the gear seats on the shoulder of the 3rd clutch shaft. See Special Tools .
Fig 4: Measuring The 3rd Drive Gear Axial Clearance Using SA91979NE
Courtesy of GENERAL MOTORS CORP.
12. Using SA9179NE  (1) measure the 3rd drive gear (803) axial clearance.
    1. Position SA9179NE  gage pointer on the top of the gear teeth.
    2. Zero the gage.
    3. Lift up on the 3rd drive gear (803) to measure the clearance.
    4. Measure the axial clearance in 3 different locations by rotating the 3rd drive gear.
    5. Average the 3 measurements for the axial clearance.

       Specification:  The 3rd gear axial clearance is 0.005-0.045 mm (0.0002-0.0018 in)

13. If the clearance exceeds the specification, replace the 3rd drive gear thrust bearing race (800) with the correct thickness.
14. If the clearance exceeds the maximum with the thickest bearing race (800), inspect the following:
    • 3rd driven gear (805) not installed completely
    • 3rd drive gear (803) worn thrust surface
    • 3rd drive gear thrust bearing (801) worn or damaged
    • 3rd driven gear (805) worn thrust surface
15. If the clearance is lower than the specifications with the thinnest bearing race (800), inspect for burrs or contamination of debris between the bearing thrust surfaces.
Fig 5: 3rd Driven Gear Retaining Ring & Cap Removed
Courtesy of GENERAL MOTORS CORP.
16. Install the 3rd driven gear retaining ring (806) on the 3rd clutch shaft (823).
17. Install the 3rd driven gear retaining ring cap (807).
18. Install the 3rd driven gear retaining ring cap 24 mm retaining ring (808).
19. Install the 3rd clutch shaft 26.5 mm washer (809). The correct thickness of the washer will be determined during the installed height measurement procedure. Refer to 3rd Clutch Shaft Installed Height Measurement .