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Output 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: 1st/2nd Driven Gear Output Shaft & Components Removed
    GM1344624Courtesy of GENERAL MOTORS CORP.
  1. Install the following components on the output shaft:
    • The 1st/2nd driven gear (523)
    • The 1st/2nd driven gear 65 x 83 x 4.5 mm thrust bearing (522)
    • The 1st/2nd idler gear 57 x 65 x 28.7 mm inner bearing (521)
    • The 1st/2nd idler gear (520) with shoulder side down
    • The 1st/2nd idler gear 56 x 878.5 x 5.5 mm thrust bearing (519)
    • The 1st driven gear 56 mm selective spacer (518)
    2. Fig 2: Measuring Between The Straight Edge & Roller Bearings Using A Feeler Gage
    GM1203927Courtesy of GENERAL MOTORS CORP.
  2. Put a straight edge across the top of the 1st/2nd idler gear thrust bearing (519).
  3. Using a feeler gage measure between the straight edge and the roller bearings on the 1st/2nd idler gear thrust bearing (519) in 3 places. Use the average of the 3 measurements as the actual clearance.
  4. Measure the 1st/2nd idler gear (520) axial clearance in at least 3 places on the gear. Use the average of the 3 measurements as the actual clearance.

    Specification:  1st/2nd idler gear clearance 0.005-0.040 mm (0.0002-0.0016 in)

  5. If the measurement exceeds the specifications, remove and measure the thickness of the 1st driven gear 56 mm selective spacer (518).
  6. Select and install a new 1st driven gear 56 mm selective spacer (518) in order to obtain the specified clearance. Measure the clearance again to ensure that the 1st/2nd idler gear is within specifications.
    7. Fig 3: 3rd/4th Driven Gear Output Shaft & Components Removed
    GM1203924Courtesy of GENERAL MOTORS CORP.
  7. Install the following components on the output shaft:
    • The 1st driven gear (517) with the gear protrusion facing up
    • The 3rd/4th driven gear (500) with the gear protrusion facing up
    • The 3rd/4th driven gear 50.2 mm selective spacer (501)
    • The 3rd/4th driven gear 39 mm split retaining rings (502)
    • The 3rd/4th driven gear 39 mm retaining ring cap (503)
    • The 3rd/4th driven gear 39 mm retaining ring cap retainer (504)
    8. Fig 4: Measuring The Clearance Between The 3rd/4th Driven Gear & 3rd/4th Driven Gear Using A Feeler Gage
    GM1203928Courtesy of GENERAL MOTORS CORP.
  8. Measure the clearance between the 3rd/4th driven gear (500) and the 3rd/4th driven gear 50.2 mm selective spacer (501) with a feeler gage (1) in at least 3 places. Use the average of the 3 measurements as the actual clearance.

    Specification:  The clearance between the 3rd/4th driven gear and the 3rd/4th driven gear selective spacer 0.005-0.040 mm (0.0002-0.0016 in).

  9. If the measurement exceeds 0.040 mm (0.016 in), remove and measure the thickness of the 3rd/4th driven gear 52 mm selective spacer (501).
  10. Select and install a new 3rd/4th driven gear 52 mm selective spacer (501) in order to obtain the specified clearance, then check for the proper clearance again.
    11. Fig 5: 5th Driven Gear Output Shaft & Components Removed
    GM1203930Courtesy of GENERAL MOTORS CORP.
  11. Install the following components on the output shaft:
    • The 5th driven gear spacer (505)
    • The 5th driven gear inner bearing (506)
    • The 5th driven gear (507)
    • The 5th/reverse synchronizer hub (509)
    12. Fig 6: DT 46509 & 5th/Reverse Synchronizer Hub
    GM1203931Courtesy of GENERAL MOTORS CORP.
  12. Using a hydraulic press and DT 46509  complete the installation of the 5th/reverse synchronizer hub (509). See Special Tools .
    13. Fig 7: Measuring The 5th Driven Gear Axial Clearance
    GM1507158Courtesy of GENERAL MOTORS CORP.
  13. Measure the 5th driven gear (507) axial clearance.
    1. Install SA9179NE  on the 5th driven gear.
    2. Zero the gage.
    3. Lift up on the 5th driven gear and record the measurement.

      Specification:  5th driven gear axial clearance 0.12-0.27 mm (0.0047-0.0106 in)

    4. If the clearance exceeds specifications inspect for excessive wear on the thrust surface of the 5th driven gear (507), the 5th/reverse synchronizer hub (509), and the shoulder of the output shaft (524).
    5. If there is not any clearance, ensure the 5th/reverse synchronizer hub (509) is completely installed and there are no burrs or debris between the gears.
    14. Fig 8: Reverse Driven Gear Output Shaft & Components Removed
    GM1344625Courtesy of GENERAL MOTORS CORP.
  14. Install the following components on the output shaft (524):
    • The 5th/reverse synchronizer sleeve (508)
    • The reverse driven gear 31 x 40 x 14.5 mm inner bearing race (510)
    • The reverse driven gear 40 x 46 x 14.5 mm inner bearing (511)
    • The reverse driven gear (512)
    15. Fig 9: Installing Rear Bearing & Output Shaft Using DT 46509 & Hydraulic Press
    GM1203933Courtesy of GENERAL MOTORS CORP.
  15. Using the DT 46509  and a hydraulic press, install the output shaft 31 x 93 x 19 mm rear bearing (514) on the output shaft (524). See Special Tools .
    16. Fig 10: Measuring The Axial Clearance For Reverse Driven Gear
    GM1507159Courtesy of GENERAL MOTORS CORP.
  16. Measure the reverse driven gear (512) axial clearance.
    1. Install SA9179NE  on the reverse driven gear.
    2. Zero the gage.
    3. Lift up on the reverse driven gear and record the measurement.

      Specification:  Reverse driven gear axial clearance 0.10-0.25 mm (0.0039-0.0098 in)

    4. If the clearance exceeds specifications inspect for excessive wear on the thrust surface of the reverse driven gear (512) or the 5th/reverse synchronizer hub (509).
    5. If there is not any clearance, ensure the output shaft rear bearing (514) is completely installed and there are no burrs or debris between the gears.
    17. Fig 11: View Of Output Shaft Washer & Retaining Nut
    GM1203934Courtesy of GENERAL MOTORS CORP.
  17. Install an output shaft washer (515) in the direction as shown.
  18. Loosely install an output shaft retaining nut (516).
    19. Fig 12: Holding Output Shaft With Wrench Mounted In A Vise
    GM1203935Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Do not use an impact wrench to tighten the nut.
    • The nut is left handed thread.
  19. To tighten the retaining nut (516), use an adjustable wrench mounted in a vise. Securely hold the output shaft in the adjustable wrench while tightening.

    Tighten:  Tighten the nut to 167 N.m (123 lb ft).

    20. Fig 13: Staking Output Shaft Nut In Place On Output Shaft
    GM1203936Courtesy of GENERAL MOTORS CORP.
  20. Using a 3.5 mm (9/64 in) punch (b), stake the output shaft nut (516) in place on the output shaft (524) to the specified depth (a).

    Specification:  Stake the nut to 0.7-1.3 mm (0.03-0.05 in.)

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