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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 >> Shafts and Clutch Assemblies Installation

Shafts and Clutch Assemblies Installation

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.
CAUTION: This procedure requires 3 technicians. Each technician needs to remove or install a complete shaft assembly in order to prevent personal injury.
    Fig 1: Mainshaft Complete Assembly, Output Shaft, Clutch Shaft & Torque Converter Housing
    GM1203370Courtesy of GENERAL MOTORS CORP.
  1. Install the 2nd clutch housing 46 x 62.95 x 4.62 mm thrust bearing (750) into the torque converter housing (150) with the rounded shoulder down.
  2. Place the reverse shift fork shaft (428) so the large chamfered hole is facing the reverse shift fork bolt hole of the reverse shift fork (924) when installed in the torque converter housing (150).
  3. Engage the reverse shift fork (924) with the 5th/reverse synchronizer ring (508) on the output shaft assembly (535).
  4. Using 3 technicians, join the mainshaft assembly (640), output shaft assembly (535), and the 1st/2nd clutch shaft assembly (755) together.
    5. Fig 2: Reverse Shift Fork, Washer & Bolt
    GM1203368Courtesy of GENERAL MOTORS CORP.
  5. With all 3-clutch shaft assemblies installed together, position the 3 clutch shaft assemblies above the torque converter housing, lower the clutch assemblies into the torque converter housing, and at the same time position the reverse shift fork (924) onto the reverse shift fork shaft (428).
  6. Position the 3 clutch shaft assemblies until all 3-clutch shaft assemblies are properly seated in the torque converter housing assembly (150).
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the reverse shift fork bolt (926) and a new reverse shift fork washer (925).

    Tighten:  Tighten the bolt to 14 N.m (10 lb ft).

  8. Bend the tab of the washer over the bolt head.
    9. Fig 3: 1st/2nd Clutch Shaft Lube Fluid Pipe & Retainer Bolt
    GM1347213Courtesy of GENERAL MOTORS CORP.
  9. Install the 1st/2nd clutch shaft feed pipe (122) into the torque converter housing (150).
  10. Install the 1st/2nd clutch shaft lube fluid pipe M6 x 1.0 x 12 mm retainer bolt (123).

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

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