LEMON Manuals: Even more car manuals for everyone
Home >> Pontiac >> 2009 >> Vibe Base, 2.4 0, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Automatic Transmission - MVB 4 Speed) >> Repair Instructions - Off Vehicle >> Transmission Assemble >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Installing Front Differential Side Gear
    GM2012805Courtesy of GENERAL MOTORS CORP.
  1. Install the front differential side gear.
    2. NOTE: When installing them, set the alignment of the front differential pinions perpendicular to that of the side gear and rotate them so that their holes are aligned with the holes in the differential case.
  2. After applying ATF to the 2 front differential side gears, 2 front differential side gear thrust washers, 2 front differential pinions and 2 front differential pinion thrust washers, install them to the front differential case.
    3. Fig 2: Aligning Lock Pin Holes In Pinion Shaft And Front Differential Case
    GM2012808Courtesy of GENERAL MOTORS CORP.
  3. Install the front No. 1 differential pinion shaft so as to align the lock pin holes in the pinion shaft and front differential case.
  4. Inspect the differential side gear backlash.
    5. Fig 3: Installing Pinion Shaft Straight Pin Using A Pin Punch And A Hammer
    GM2012809Courtesy of GENERAL MOTORS CORP.
  5. Using a pin punch and a hammer, install the pinion shaft straight pin.
    6. Fig 4: Staking Differential Case Using A Chisel And A Hammer
    GM2012811Courtesy of GENERAL MOTORS CORP.
  6. Using a chisel and a hammer, stake the differential case.
    7. Fig 5: Heating Front Differential Ring Gear Using ATF And A Heater
    GM2012813Courtesy of GENERAL MOTORS CORP.
  7. Install the front differential ring gear.
  8. Using ATF and a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).
  9. Clean the contact surface of the front differential case.
    10. Fig 6: Installing Ring Gear Lock Plates With Bolts
    GM2012815Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  10. Install the 4 new ring gear lock plates with the 8 bolts and tighten to 88 N.m (65 lb ft).
    11. Fig 7: Staking Ring Gear Lock Plate
    GM2012825Courtesy of GENERAL MOTORS CORP.
  11. Stake the ring gear lock plate.
    12. Fig 8: Installing Front Differential Case Rear Tapered Roller Bearing Inner Race To Differential Case Using A Press
    GM2012827Courtesy of GENERAL MOTORS CORP.
  12. Using a press (1), install the front differential case rear tapered roller bearing inner race to the differential case.
    13. Fig 9: Installing Shim And Bearing Outer Race To Transaxle Case Using A Press
    GM2012829Courtesy of GENERAL MOTORS CORP.
  13. Using a press (2), install the shim and bearing outer race to the transaxle case.
    14. Fig 10: Installing Front Differential Case Front Tapered Roller Bearing Inner Race To Differential Case Using A Press
    GM2012831Courtesy of GENERAL MOTORS CORP.
  14. Using a press, install the front differential case front tapered roller bearing inner race to the differential case.
    15. Fig 11: Install Front Differential Case Front Tapered Roller Bearing To Transaxle Housing Using A Press
    GM2012833Courtesy of GENERAL MOTORS CORP.
  15. Using a press (1), install the front differential case front tapered roller bearing to the transaxle housing.
    16. Fig 12: Checking Each Bearing Position And Installation Direction
    GM2012597Courtesy of GENERAL MOTORS CORP.
  16. Check each bearing position and installation direction.
  17. Inspect the differential case tapered roller bearing preload.
  18. Coat the front differential case and bearing with ATF and install them to the transaxle case.
    19. Fig 13: Locating Transaxle Housing Bolts
    GM2012598Courtesy of GENERAL MOTORS CORP.
  19. Install the transaxle housing with the 14 bolts (1).
    • Tighten bolt A to 29 N.m (21 lb ft) .
    • Tighten bolt B to 22 N.m (16 lb ft) .
    20. Fig 14: Measuring Preload Of The Differential Gear
    GM2012599Courtesy of GENERAL MOTORS CORP.
  20. Using J-35405:  Differential Preload Wrench and a small torque wrench, measure the preload of the differential gear. Refer to Transmission General Specifications  for Preload.

    If the preload is not within the specification, remove the differential from the transaxle case.

    Select a new transaxle case side adjusting shim in accordance with the specification. Refer to Transmission General Specifications  for Adjusting Shim Thickness.

    21. Fig 15: Driving In No. 1 Transaxle Case Oil Seal
    GM2012600Courtesy of GENERAL MOTORS CORP.
  21. Coat the lip of a new No. 1 transaxle case oil seal with MP grease.
  22. Drive in the No. 1 transaxle case oil seal.

    Oil seal driven in depth:  -0.5 to 0.5 mm (-0.0197 to 0.0197 in)

    23. Fig 16: Driving In Front Transaxle Case Oil Seal
    GM2012602Courtesy of GENERAL MOTORS CORP.
  23. Coat the lip of a new front transaxle case oil seal with MP grease.
  24. Drive in the front transaxle case oil seal.

    Oil seal driven in depth:  2.2 to 3.2 mm (0.0866 to 0.126 in)

    25. Fig 17: Installing No. 1 Transaxle Case Plate Onto Transaxle Case
    GM2012604Courtesy of GENERAL MOTORS CORP.
  25. Install the No. 1 transaxle case plate (1) onto the transaxle case.
    26. Fig 18: Installing Front Drive Pinion Rear Tapered Roller Bearing To Transaxle Case
    GM2012605Courtesy of GENERAL MOTORS CORP.
  26. Install the front drive pinion rear tapered roller bearing to the transaxle case.
    27. Fig 19: Installing A Front Drive Pinion Front Tapered Roller Bearing To Transaxle Housing Using A Press
    GM2012607Courtesy of GENERAL MOTORS CORP.
  27. Install the thrust bearing to the transaxle housing.
  28. Using a press, install a new front drive pinion front tapered roller bearing to the transaxle housing.
    29. Fig 20: Locating Differential Gear Lube Apply Tube
    GM2012410Courtesy of GENERAL MOTORS CORP.
  29. Install the differential gear lube apply tube (1) to the transaxle housing.
    30. Fig 21: Identifying Bearing Lock Plate Bolt
    GM2012409Courtesy of GENERAL MOTORS CORP.
  30. Install the bearing lock plate to the transaxle housing with the bolt (1) and tighten to 11 N.m (8 lb ft).
    31. Fig 22: View Of Counter Drive Gear Hole Snap Ring & Transaxle Case
    GM2012436Courtesy of GENERAL MOTORS CORP.
  31. Using a screwdriver, install the counter drive gear hole snap ring to the transaxle case.
    32. Fig 23: Installing Counter Drive Gear Bearing Outer Race LH To Transaxle Case
    GM2012612Courtesy of GENERAL MOTORS CORP.
  32. Install the counter drive gear bearing outer race LH to the transaxle case.
  33. Install the counter drive gear bearing LH to the transaxle case.
    34. Fig 24: Installing Counter Drive Gear Bearing Outer Race RH To Transaxle Case
    GM2012613Courtesy of GENERAL MOTORS CORP.
  34. Install the counter drive gear bearing outer race RH to the transaxle case.
  35. Install the counter drive gear bearing RH to the transaxle case.
    36. Fig 25: Installing Manual Valve Lever Shaft Oil Seal
    GM2012615Courtesy of GENERAL MOTORS CORP.
  36. Coat the lip of a new manual valve lever shaft oil seal with MP grease.
  37. Install the new manual valve lever shaft oil seal.

    Oil seal driven in depth:  -0.5 to 0.5 mm (-0.020 to 0.020 in)

    38. Fig 26: Installing Differential Drive Pinion To Counter Driven Gear Using A Press
    GM2012619Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • When replacing the counter driven gear, replace the counter drive gear in the transaxle case as well.
    • Press in the differential drive pinion until it comes into contact with the counter driven gear.
  38. Using a press (1), install the differential drive pinion to the counter driven gear.
    39. Fig 27: Installing Differential Drive Pinion Plug
    GM2012620Courtesy of GENERAL MOTORS CORP.
  39. Install a new differential drive pinion plug (3) to the differential drive pinion.

    Specification:  Standard clearance - 2.5 to 3.5 mm (0.0984 to 0.137 in).

    40. Fig 28: Installing Counter Driven Gear And Drive Pinion Thrust Bearing To Transaxle Case
    GM2012621Courtesy of GENERAL MOTORS CORP.
  40. Install the counter driven gear and drive pinion thrust bearing to the transaxle case.
  41. Coat the parking lock pawl shaft with ATF.
    42. Fig 29: View Of Parking Lock Pawl Torsion Spring, Parking Lock Pawl & Transaxle Case
    GM2012397Courtesy of GENERAL MOTORS CORP.
    NOTE: Check that the parking lock pawl moves smoothly.
  42. Install the parking lock pawl, parking lock pawl shaft torsion spring (1) and parking lock pawl shaft to the transaxle case.
    43. Fig 30: View Of Manual Valve Lever Shaft & Transaxle Case
    GM2012393Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not damage the oil seal lip.
  43. Install the manual valve lever shaft to the transaxle case.
    44. Fig 31: View Of Parking Lock Rod & Manual Valve Lever
    GM2012385Courtesy of GENERAL MOTORS CORP.
  44. Install the parking lock rod to the manual valve lever.
  45. Coat the manual valve lever sub-assembly with ATF.
  46. Install the manual valve lever and a new manual valve lever spacer to the manual valve lever shaft.
    47. Fig 32: Driving Out Manual Valve Lever Shaft Spring Pin Using A Pin Punch And Hammer
    GM2012384Courtesy of GENERAL MOTORS CORP.
  47. Using a pin punch and hammer, drive in the pin.
    48. Fig 33: Turning Spacer And Lever Shaft
    GM2012626Courtesy of GENERAL MOTORS CORP.
  48. Turn the spacer and lever shaft (1) to align the small hole for locating the staking position mark on the lever shaft.
  49. Using a pin punch, stake the spacer through the small hole.
  50. Check that the spacer does not turn.
    51. Fig 34: View Of Manual Valve Lever Shaft Retainer Spring & Manual Valve Lever Shaft
    GM2012378Courtesy of GENERAL MOTORS CORP.
  51. Install the manual valve lever shaft retainer spring to the manual valve lever shaft.
    52. Fig 35: View Of Cam Guide, Bracket, Transaxle Case & Bolts
    GM2012376Courtesy of GENERAL MOTORS CORP.
  52. Install the parking lock pawl bracket, parking lock rod and cam guide sleeve to the transaxle case with the 3 bolts and tighten to 20 N.m (15 lb ft).
    53. Fig 36: Installing Counter Drive Gear To Transaxle Case Using A Press
    GM2012629Courtesy of GENERAL MOTORS CORP.
  53. Using a press (1), install the counter drive gear to the transaxle case.
    54. Fig 37: Installing Planetary Gear Assembly To Transaxle Case Using A Press
    GM2012630Courtesy of GENERAL MOTORS CORP.
  54. Using a press (1), install the planetary gear assembly to the transaxle case.
    55. Fig 38: View Of Counter Driven Gear & Parking Lock Pawl
    GM2012367Courtesy of GENERAL MOTORS CORP.
  55. Install the counter drive gear nut.
  56. Secure the counter driven gear with the parking lock pawl.
    57. Fig 39: Installing A New Lock Washer And Nut
    GM2012633Courtesy of GENERAL MOTORS CORP.
  57. Using DT-49190:  Counter Gear Nut Wrench, install a new lock washer and nut and tighten to 280 N.m (207 lb ft).
    58. Fig 40: Measuring Rotating Torque While Turning Counter Drive Gear At 60 Turns Per Minute
    GM2012635Courtesy of GENERAL MOTORS CORP.
  58. Using DT-49190:  Wrench, measure the rotating torque while turning the counter drive gear at 60 turns per minute. Tighten the drive gear to 0.20-0.49 N.m (1.8-4.3 lb in).
    59. Fig 41: Staking Lock Nut Washer
    GM2012636Courtesy of GENERAL MOTORS CORP.
  59. Stake the lock nut washer
    60. Fig 42: Identifying O-Rings & No. 2 1ST And Reverse Brake Piston
    GM2012365Courtesy of GENERAL MOTORS CORP.
  60. Coat 2 new No. 2 1st and reverse brake piston O-rings (1) with ATF, and install them to the No. 2 1st and reverse brake piston.
    61. Fig 43: View Of No. 2 1ST And Reverse Brake Piston
    GM2012638Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not damage the oil seal lip.
  61. Coat the No. 2 1st and reverse brake piston with ATF, and install it to the transaxle case.
    62. Fig 44: Removing/Installing Snap Ring Using A Press And A Screwdriver
    GM2012362Courtesy of GENERAL MOTORS CORP.
  62. Install the 1st and reverse brake return spring sub-assembly to the transaxle case.
  63. Using a press and a screwdriver, install the snap ring.
    64. Fig 45: Identifying 1ST And Reverse Brake Disc Components
    GM2012639Courtesy of GENERAL MOTORS CORP.
  64. Install the 1st and reverse brake disc.
  65. Install the 4 plates (1), 4 discs (3) and flange (2) to the transaxle case.
  66. Using a screwdriver, install the snap ring.
  67. Inspect the pack clearance of 1st and reverse brake.
    68. Fig 46: Measuring 1ST And Reverse Brake Clearance
    GM2012640Courtesy of GENERAL MOTORS CORP.
  68. Using a dial indicator (1), measure the 1st and reverse brake clearance while pressing the discs and plates from the rear side.

    Specification:  Pack clearance - 0.81 to 1.20 mm (0.0318 to 0.0472 in).

    There are 4 different thicknesses of flanges available. Refer to Transmission General Specifications  for Reverse Brake Flange Thickness Chart.

    If the clearance is not within the specified range, select a new reverse brake flange.

  69. Check that the 1st and reverse brake piston moves when compressed air 392 kPa (57 psi) is applied to the oil hole.
    70. Fig 47: Installing Planetary Sun Gear And Needle Roller Bearing To Planetary Gear Assembly
    GM2012643Courtesy of GENERAL MOTORS CORP.
  70. Install the planetary sun gear and needle roller bearing to the planetary gear assembly.
    71. Fig 48: View Of O-Rings From 2ND Brake Cylinder
    GM2012357Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not damage the O-rings.
  71. Coat 2 new 2nd brake cylinder O-rings with ATF, and install them into the 2nd brake cylinder.
    72. Fig 49: View Of O-Rings, 2ND Brake Piston & 2ND Brake Cylinder
    GM2012644Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not damage the O-rings when pressing the 2nd brake piston into the 2nd brake cylinder by hand.
  72. Coat the 2nd brake piston with ATF, and install it into the 2nd brake cylinder.
    73. Fig 50: Identifying 2ND Brake Piston Return Spring Subassembly & 2ND Brake Cylinder
    GM2012355Courtesy of GENERAL MOTORS CORP.
  73. Install the piston return spring.
    74. Fig 51: Removing/Installing Snap Ring & 2ND Brake Piston Using A Press
    GM2012354Courtesy of GENERAL MOTORS CORP.
  74. Compress the piston return spring with a press.
    75. NOTE: Make sure that the end gap of the snap ring is not aligned with the piston return spring claw.
  75. Using a screwdriver, install the snap ring.
    76. Fig 52: Identifying Retainer & No. 2 One-Way Clutch
    GM2012353Courtesy of GENERAL MOTORS CORP.
  76. Install the outer race retainer (1) to the No. 2 one-way clutch.
    77. Fig 53: View Of 2ND Brake Assembly, No. 2 One-Way Clutch And Rear Planetary Gear
    GM2012352Courtesy of GENERAL MOTORS CORP.
  77. Install the No. 2 one-way clutch and 2nd brake piston assembly to the rear planetary gear assembly.
    78. Fig 54: View Of No. 2 Thrust Bearing Race, Planetary Gear Thrust Needle Roller Bearing, Thrust Bearing Race & Rear Planetary Gear Assembly
    GM2012647Courtesy of GENERAL MOTORS CORP.
  78. Install the No. 2 thrust bearing race, the planetary gear thrust needle roller bearing and thrust bearing race to the rear planetary gear assembly.
    79. Fig 55: View Of Rear Planetary Gear Assembly & Transaxle Case
    GM2012648Courtesy of GENERAL MOTORS CORP.
  79. Install the rear planetary gear assembly to the transaxle case.
  80. Using a screwdriver, install the snap ring.
    81. Fig 56: Turning Rear Planetary Gear Assembly
    GM2012349Courtesy of GENERAL MOTORS CORP.
  81. Check that the rear planetary gear assembly (1) turns freely counterclockwise and locks when turned clockwise.
    82. Fig 57: View Of No. 2 One-Way Clutch
    GM2012347Courtesy of GENERAL MOTORS CORP.
  82. Install the 2nd brake piston sleeve to the transaxle case.
    83. Fig 58: Identifying Discs, No. 1-2ND Brake Flanges And 2ND Brake Flanges & Transaxle Case
    GM2012649Courtesy of GENERAL MOTORS CORP.
  83. Install the 4 discs (5), 3 No. 1-2nd brake flanges (3) and 2 2nd brake flanges (1, 4) to the transaxle case.
    84. Fig 59: Exploded View Of Snap Rings
    GM2012346Courtesy of GENERAL MOTORS CORP.
  84. Using a screwdriver, install the 2 snap rings (1, 2) to the transaxle case.
    85. Fig 60: Measuring Pack Clearance Of 2ND Brake
    GM2012650Courtesy of GENERAL MOTORS CORP.
  85. Inspect the pack clearance of 2nd brake.
    86. NOTE: If the clearance is not within the specified range, select a new brake flange.
  86. Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air 392-785 kPa (57-114 psi).

    Specification:  Pack clearance - 0.85 to 1.24 mm (0.0334 to 0.0488 in)

    There are 4 different thicknesses of flanges available. Refer to Transmission General Specifications  for 2nd Brake Flange Thickness Chart.

    87. Fig 61: View Of One-Way Clutch Assembly, No. 2 Planetary Carrier Thrust Washer & Rear Planetary Sun Gear
    GM2012345Courtesy of GENERAL MOTORS CORP.
  87. Install the No. 2 thrust washer to the rear planetary gear assembly.
  88. Install the one-way clutch assembly to the rear planetary sun gear assembly.
    89. Fig 62: Turning Rear Planetary Sun Gear One-Way Clutch
    GM2012344Courtesy of GENERAL MOTORS CORP.
  89. Inspect the one-way clutch assembly.
  90. Hold the rear planetary sun gear, turn the one-way clutch and check that the one-way clutch turns freely counterclockwise and locks when turned clockwise.
    91. Fig 63: View Of Thrust Needle Roller Bearing, Washer & Rear Planetary Sun Gear
    GM2012652Courtesy of GENERAL MOTORS CORP.
  91. Install the thrust needle roller bearing and the washer to the rear planetary sun gear.
    92. Fig 64: View Of Rear Planetary Sun Gear & Transaxle Case
    GM2012339Courtesy of GENERAL MOTORS CORP.
  92. Install the rear planetary sun gear assembly.
    93. Fig 65: Exploded View Of Rear No. 2 Planetary Sun Gear Thrust Needle Roller Bearing
    GM2012653Courtesy of GENERAL MOTORS CORP.
  93. Install the rear No. 2 planetary sun gear thrust needle roller bearing.
    94. Fig 66: View Of Direct Clutch Hub & Transaxle Case
    GM2012337Courtesy of GENERAL MOTORS CORP.
  94. Install the direct clutch hub.
    95. Fig 67: Exploded View Of No. 3 Thrust Bearing Race, Thrust Needle Roller Bearing, C-2 Hub Thrust Bearing Race & Direct Clutch Hub.
    GM2012655Courtesy of GENERAL MOTORS CORP.
  95. Install the No. 3 thrust bearing race, the thrust needle roller bearing and the C-2 hub thrust bearing race to the direct clutch hub.
    96. Fig 68: Measuring Flange Thickness (Dimension A)
    GM2012656Courtesy of GENERAL MOTORS CORP.
  96. Install the 2nd coast and overdrive brake disc.
  97. Measure the flange thickness. (Dimension A)
    98. Fig 69: Identifying Discs, Plates, Flange & Transaxle Case
    GM2012658Courtesy of GENERAL MOTORS CORP.
  98. Install the 2 discs (3), 2 plates (2) and flange (1) to the transaxle case.
    99. Fig 70: View Of Direct Clutch Drum O-Ring & Direct Clutch Drum
    GM2012330Courtesy of GENERAL MOTORS CORP.
  99. Coat a new O-ring (1) with ATF and install it to the direct clutch drum.
    100. Fig 71: Identifying Piston O-Rings & Direct Clutch Piston
    GM2012328Courtesy of GENERAL MOTORS CORP.
  100. Coat 2 new O-rings (1) with ATF and install them to the direct clutch piston.
  101. Coat the direct clutch drum with ATF.
    102. Fig 72: Aligning A Cutout On Intermediate Shaft Assembly With Matchmark On Direct Clutch Drum
    GM2012661Courtesy of GENERAL MOTORS CORP.
  102. Align a cutout on the intermediate shaft assembly with the matchmark on the direct clutch drum and install the direct clutch drum to the intermediate shaft assembly.
    103. Fig 73: View Of Direct Clutch Piston And Intermediate Shaft
    GM2012663Courtesy of GENERAL MOTORS CORP.
  103. Coat the direct clutch piston with ATF and install it to the intermediate shaft.
    104. Fig 74: Exploded View Of Direct Clutch Return Spring & Direct Clutch Piston
    GM2012664Courtesy of GENERAL MOTORS CORP.
  104. Install the direct clutch return spring onto the direct clutch piston.
  105. Compress the piston return springs with a press.
    106. NOTE:
    • Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in) from the snap ring groove to prevent the spring seat from being deformed.
    • Do not expand the snap ring excessively.
  106. Using snap ring pliers, install the snap ring to the direct clutch drum.
    107. Fig 75: Locating Snap Ring, Rear Clutch Flanges, Discs, Direct Clutch Flange & Intermediate Shaft
    GM2012667Courtesy of GENERAL MOTORS CORP.
  107. Coat the 3 rear clutch flanges (3), 3 discs (4) and direct clutch flange (1) with ATF and install them to the intermediate shaft.
  108. Install the snap ring (2) to the intermediate shaft.
    109. Fig 76: Identifying Snap Ring, Plates, Discs, Flange & Intermediate Shaft
    GM2012677Courtesy of GENERAL MOTORS CORP.
  109. Coat the 3 plates (4), 3 discs (3) and flange (2) with ATF, and install them to the intermediate shaft.
  110. Install the snap ring (1) to the intermediate shaft.
    111. Fig 77: Measuring Reverse Clutch Pack Clearance
    GM2012678Courtesy of GENERAL MOTORS CORP.
  111. Inspect the pack clearance of the reverse clutch.
  112. Install the intermediate shaft and thrust needle roller bearing to the rear transaxle cover.
    113. NOTE: If the clearance is not within the specified range, select a new clutch flange.
  113. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air 392 kPa (57 psi).

    Specification:  Pack clearance - 0.62 to 1.16 mm (0.0244 to 0.0456 in)

    There are 4 different thicknesses of flanges available. Refer to Transmission General Specifications  for Clutch Flange Thickness Chart.

    114. Fig 78: Measuring Forward Clutch Pack Clearance
    GM2012679Courtesy of GENERAL MOTORS CORP.
  114. Inspect the pack clearance of the direct clutch.
  115. Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover.
    116. NOTE: If the clearance is not within the specified range, select a new clutch flange.
  116. Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air 392 kPa (57 psi).

    The direct and reverse clutch will come out as compressed air is applied.

    Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a press or the equivalent so that the pressure is not applied to the direct and reverse clutch.

    Specification:  Pack clearance - 0.62 to 1.02 mm (0.0244 to 0.0402 in)

    There are 4 different flanges thicknesses. Refer to Transmission General Specifications  for Direct Clutch Flange Thickness Chart.

    117. Fig 79: View Of Intermediate Shaft Assembly & Transaxle Case
    GM2012315Courtesy of GENERAL MOTORS CORP.
  117. Install the intermediate shaft assembly to the transaxle case.
    118. Fig 80: Measuring Distance Between 2ND Coast, Overdrive Brake Flange And Straightedge (Dimension B)
    GM2012680Courtesy of GENERAL MOTORS CORP.
  118. Inspect the 2nd coast and overdrive brake clearance.
  119. As shown in the illustration, place a straightedge on the transaxle case and measure the distance between the 2nd coast and overdrive brake flange and the straightedge using vernier calipers. (Dimension B)
    120. Fig 81: Measuring Distance Between Transaxle Rear Cover And Straightedge Using Vernier Calipers (Dimension C)
    GM2012681Courtesy of GENERAL MOTORS CORP.
    NOTE: If the clearance is not within the specified range, select a new brake flange.
  120. As shown in the illustration, place a straightedge on the overdrive brake piston and measure the distance between the transaxle rear cover and straightedge using vernier calipers. (Dimension C)

    Calculate the piston stroke value using the following formula.

    Formula: (Dimension A + Dimension B) - Dimension C

    Specification:  Pack clearance - 2.10 to 2.49 mm (0.0826 to 0.0980 in)

    There are 4 different thicknesses of flanges available. Refer to Transmission General Specifications  for 2nd Coast and Overdrive Flange Thickness Chart.

    121. Fig 82: View Of Rear Clutch Drum Thrust Needle Roller Bearing
    GM2012682Courtesy of GENERAL MOTORS CORP.
  121. Install the rear clutch drum thrust needle roller bearing.
  122. Install the bearing to the intermediate shaft.
    123. Fig 83: View Of Rear Transaxle Cover, Rear Transaxle Cover & Transaxle Case
    GM2012279Courtesy of GENERAL MOTORS CORP.
  123. Inspect the intermediate shaft assembly.
  124. Install the rear transaxle cover with the 11 bolts and tighten to 25 N.m (18 lb ft).
    125. Fig 84: Measuring Intermediate Shaft End Play
    GM2012271Courtesy of GENERAL MOTORS CORP.
  125. Using a dial indicator, measure the intermediate shaft end play.

    Specification:  End play - 0.21 to 0.96 mm (0.00826 to 0.0377 in)

    If the end play is not as specified, select and replace the rear clutch drum thrust needle roller bearing.

    There are 2 different thicknesses of trust needle roller bearings available.

    • Color - Brown, Thickness - 0.785 mm (0.0309 in)
    • Color - Black, Thickness - 1.1 mm (0.0433 in)
  126. Remove the 11 bolts and the rear transaxle cover.
    127. Fig 85: View Of Transaxle Case Gaskets
    GM2012306Courtesy of GENERAL MOTORS CORP.
  127. Install the 4 new gaskets to the transaxle case.
    128. Fig 86: Installing Needle Roller Bearing Into Rear Transaxle Cover Using A Press
    GM2012683Courtesy of GENERAL MOTORS CORP.
  128. Coat a new needle roller bearing with ATF.
  129. Using a press (1), install the needle roller bearing into the rear transaxle cover.

    Specification:  Standard clearance - 25.1 mm (0.988 in)

    130. Fig 87: Compressing Oil Seal Rings From Both Sides To Reduce Dimension A
    GM2012684Courtesy of GENERAL MOTORS CORP.
  130. Compress the 3 oil seal rings from both sides to reduce dimension A.

    Specification:  Dimension A - 5.0 mm (0.197 in)

  131. Coat 3 oil seal rings with ATF and install them to the rear transaxle cover.
    132. Fig 88: Identifying Overdrive Brake Piston 2ND Coast O-Rings
    GM2012290Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not damage the O-rings.
  132. Coat 2 new O-rings (1, 2) with ATF and install them to the 2nd coast and overdrive brake piston.
    133. Fig 89: View Of 2ND Coast And Overdrive Brake Piston
    GM2012685Courtesy of GENERAL MOTORS CORP.
  133. Install the 2nd coast and overdrive brake piston.
  134. Coat the piston with ATF and install it to the rear transaxle cover.
    135. Fig 90: View Of Overdrive Brake Return Spring Snap Ring
    GM2012282Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in) from the snap ring groove to prevent the spring seat from being deformed.
    • Do not expand the snap ring excessively.
  135. Using a press, install the overdrive brake return spring and snap ring to the rear transaxle cover.
    136. Fig 91: Installing Rear Transaxle Cover Plugs
    GM2012686Courtesy of GENERAL MOTORS CORP.
  136. Coat 4 new O-rings with ATF, and install them to the 4 rear transaxle cover plugs.
  137. Install the 4 rear transaxle cover plugs (1) to the rear transaxle cover and tighten to 7.4 N.m (66 lb in).
    138. Fig 92: View Of Transaxle Case
    GM2012687Courtesy of GENERAL MOTORS CORP.
  138. Apply sealant to the transaxle case.
    139. Fig 93: View Of Rear Transaxle Cover, Rear Transaxle Cover & Transaxle Case
    GM2012279Courtesy of GENERAL MOTORS CORP.
  139. Install the rear transaxle cover with the 11 bolts and tighten to 25 N.m (18 lb ft).
    140. Fig 94: View Of Forward Clutch Hub & Transaxle Case
    GM2012272Courtesy of GENERAL MOTORS CORP.
  140. Install the forward clutch hub sub-assembly onto the transaxle case.
    141. Fig 95: Exploded View Of Bearing & Forward Clutch Hub
    GM2012690Courtesy of GENERAL MOTORS CORP.
  141. Install the bearing to the forward clutch hub.
    142. Fig 96: Exploded View Of Input Shaft Oil Seal Ring
    GM2012266Courtesy of GENERAL MOTORS CORP.
  142. Coat a new input shaft oil seal ring with ATF, and install it to the input shaft.
    143. Fig 97: Identifying Forward Clutch Piston Ring
    GM2012264Courtesy of GENERAL MOTORS CORP.
  143. Coat a new clutch piston O-ring (1) with ATF, and install it to the forward clutch piston.
    144. Fig 98: View Of Forward Clutch Piston & Input Shaft
    GM2012693Courtesy of GENERAL MOTORS CORP.
  144. Install the forward clutch piston to the input shaft.
    145. Fig 99: View Of Return Spring, Clutch Balancer & Input Shaft
    GM2012695Courtesy of GENERAL MOTORS CORP.
  145. Install the return spring and clutch balancer to the input shaft.
    146. Fig 100: View Of Return Spring & Press
    GM2012255Courtesy of GENERAL MOTORS CORP.
  146. Using a press (1) and snap ring pliers, install the snap ring to the input shaft.
    147. Fig 101: Identifying Plates, Discs And Flange
    GM2012697Courtesy of GENERAL MOTORS CORP.
  147. Install the front clutch disc.
  148. Install the 4 plates (3), 4 discs (1) and flange (2).
  149. Using a screwdriver, install the snap ring to the input shaft.
    150. Fig 102: Measuring Pack Clearance
    GM2012699Courtesy of GENERAL MOTORS CORP.
  150. Inspect the pack clearance of the forward clutch.
    151. NOTE: If the clearance is not within the specified range, install a new brake flange.
  151. Using a dial indicator, measure the pack clearance while applying and releasing compressed air 392 kPa (57 psi).

    Specification:  Pack clearance - 1.41 to 1.80 mm (0.0555 to 0.0708 in)

    There are 4 different thicknesses of flanges available. Refer to Transmission General Specifications  for Forward Clutch Flange Thickness Chart.

    152. Fig 103: Exploded View Of Bearing & Input Shaft Assembly
    GM2012701Courtesy of GENERAL MOTORS CORP.
  152. Install the bearing to the input shaft assembly.
    153. Fig 104: View Of Input Shaft Assembly
    GM2012242Courtesy of GENERAL MOTORS CORP.
  153. Install the input shaft assembly to the transaxle case.
    154. Fig 105: Identifying Overdrive Brake Gaskets
    GM2012240Courtesy of GENERAL MOTORS CORP.
  154. Install 2 new gaskets (1, 2) to the transaxle case.
    155. Fig 106: View Of Differential Gear Assembly
    GM2012238Courtesy of GENERAL MOTORS CORP.
  155. Install the differential gear assembly to the transaxle case.
    156. Fig 107: View Of Oil Pump Assembly Bolts
    GM2012237Courtesy of GENERAL MOTORS CORP.
  156. Install the oil pump with the 7 bolts and tighten to 22 N.m (16 lb ft).
    157. Fig 108: Turning Input Shaft
    GM2012702Courtesy of GENERAL MOTORS CORP.
  157. Inspect the input shaft assembly.
  158. Make sure that the input shaft turns smoothly.
    159. Fig 109: Measuring End Play In Axial Direction
    GM2012235Courtesy of GENERAL MOTORS CORP.
  159. Inspect the input shaft end play.
  160. Measure the end play in the axial direction.

    Specification:  End play - 0.38 to 1.29 mm (0.0149 to 0.0507 in)

    If the end play is not as specified, replace the forward clutch hub thrust needle roller bearing and the stator shaft thrust needle bearing.

    161. Fig 110: View Of Transaxle Case
    GM2012703Courtesy of GENERAL MOTORS CORP.
  161. Apply sealant to the transaxle case.
    162. Fig 111: Locating Transaxle Housing Bolts
    GM2012598Courtesy of GENERAL MOTORS CORP.
  162. Install the transaxle housing with the 14 bolts.
    • Tighten Bolt 1 to 29 N.m (21 lb ft) .
    • Tighten Bolt 2 to 22 N.m (16 lb ft) .
    163. Fig 112: Identifying C-2 Accumulator Piston O-Rings
    GM2012226Courtesy of GENERAL MOTORS CORP.
  163. Coat 2 new O-rings with ATF and install them to the C-2 accumulator piston.
    164. Fig 113: Exploded View Of Spring & C-2 Accumulator Piston
    GM2012706Courtesy of GENERAL MOTORS CORP.
  164. Install the spring and C-2 accumulator piston.

    Accumulator Spring: 

    • Spring - C-2
    • Free length/Outer diameter - 17.20-66.90 mm (0.677-2.633 in)

    165. Fig 114: Identifying C-3 Accumulator Piston O-Rings
    GM2012220Courtesy of GENERAL MOTORS CORP.
  165. Coat 2 new O-rings (1) with ATF and install them to the C-3 accumulator piston.
    166. Fig 115: Exploded View Of Spring And C-3 Accumulator Piston
    GM2012707Courtesy of GENERAL MOTORS CORP.
  166. Install the spring and C-3 accumulator piston.

    Accumulator Spring: 

    • Spring - C-3
    • Free length/Outer diameter - 18.70-87.30 mm (0.736-3.437 in)
    • Color - Orange

    167. Fig 116: Identifying B-2 Accumulator Piston O-Rings
    GM2012215Courtesy of GENERAL MOTORS CORP.
  167. Coat 2 new O-rings (1) with ATF and install them to the B-2 accumulator piston.
    168. Fig 117: Identifying Spring And B-2 Accumulator Piston
    GM2012711Courtesy of GENERAL MOTORS CORP.
  168. Install the spring and B-2 accumulator piston.

    Accumulator Spring: 

    • Spring - B-2
    • Free length/Outer diameter - 15.50-66.90 mm (0.610-2.633 in)
    • Color - White

    169. Fig 118: Identifying Spring And Check Ball Body
    GM2012712Courtesy of GENERAL MOTORS CORP.
  169. Install the spring and the check ball body (1).
    170. Fig 119: Installing A New Brake Drum Gasket
    GM2012209Courtesy of GENERAL MOTORS CORP.
  170. Install a new brake drum gasket.
    171. Fig 120: Locating Transaxle Case Gasket
    GM2012208Courtesy of GENERAL MOTORS CORP.
  171. Coat a new transaxle case gasket (1) with ATF, and install it to the transaxle case.
    172. Fig 121: Identifying Transaxle Case 2ND Brake Gasket
    GM2012205Courtesy of GENERAL MOTORS CORP.
  172. Coat a new transaxle case 2nd brake gasket (1) with ATF, and install it to the transaxle case.
    173. Fig 122: Identifying Transmission Wire O-Ring
    GM2011806Courtesy of GENERAL MOTORS CORP.
  173. Coat a new O-ring (1) with ATF, and install it into the transmission wire.
    174. Fig 123: View Of Transmission Wire & Transaxle
    GM2011810Courtesy of GENERAL MOTORS CORP.
  174. Insert the transmission wire to the transaxle.
    175. Fig 124: Locating Transmission Wire Bolt
    GM2011805Courtesy of GENERAL MOTORS CORP.
  175. Install the transmission wire with the bolt and tighten to 5.4 N.m (48 lb in).
  176. Align the groove of the manual valve with the pin of the manual valve lever.
    177. Fig 125: Aligning Groove Of Manual Valve With Pin Of Manual Valve Lever
    GM2011844Courtesy of GENERAL MOTORS CORP.
  177. Temporarily install the valve body with the 13 bolts. Refer to Transmission General Specifications  for Bolt Length - 1.
    178. Fig 126: Identifying Detent Spring, Detent Spring Cover & Bolts
    GM2012716Courtesy of GENERAL MOTORS CORP.
  178. Temporarily install the detent spring (1) and detent spring cover with the 2 bolts. Refer to Transmission General Specifications  for Bolt Length - 2.
  179. Check that the manual valve lever is in contact with the center of the roller at the tip of the detent spring.
  180. Tighten the 15 bolts to 11 N.m (8 lb ft).
    181. Fig 127: Identifying ATF Temperature Sensor Bolt & Lock Plate
    GM2012204Courtesy of GENERAL MOTORS CORP.
  181. Connect the 5 solenoid connectors.
  182. Install the ATF temperature sensor (6) with the lock plate and bolt. Tighten the bolt to 11 N.m (8 lb ft).
    183. Fig 128: View Of Oil Strainer Gasket & Oil Strainer
    GM2011824Courtesy of GENERAL MOTORS CORP.
  183. Coat a new gasket (1) with ATF, and install it to the oil strainer.
    184. Fig 129: Locating Oil Strainer Bolts
    GM2011822Courtesy of GENERAL MOTORS CORP.
  184. Install the valve body oil strainer assembly to the automatic transaxle with the 3 bolts (1). Tighten the bolts to 11 N.m (8 lb ft).
    185. Fig 130: Locating Oil Pan Magnets
    GM2011820Courtesy of GENERAL MOTORS CORP.
  185. Install the 2 magnets (1) to the oil pan.
  186. Install a new oil pan gasket to the oil pan.
    187. Fig 131: View Of Oil Pan & Bolts
    GM2012721Courtesy of GENERAL MOTORS CORP.
  187. Install the oil pan with the 19 bolts and tighten to 7.8 N.m (69 lb in).
  188. Install the breather plug to the transaxle case.
    189. Fig 132: View Of Breather Plug Hose & Breather Plug
    GM2012199Courtesy of GENERAL MOTORS CORP.
  189. Install the breather plug hose to the breather plug.
  190. Coat 5 new O-rings with ATF, and install them to the 5 No. 1 transaxle case plugs.
    191. Fig 133: Locating 4 No. 1 Transaxle Case Plugs
    GM2012197Courtesy of GENERAL MOTORS CORP.
  191. Install the 4 No. 1 transaxle case plugs (1) to the transaxle housing and transaxle case and tighten to 7.4 N.m (66 lb in).
    192. Fig 134: Identifying No. 1 Transaxle Case Plug & Transaxle Case
    GM2012198Courtesy of GENERAL MOTORS CORP.
  192. Install the No. 1 transaxle case plug (1) to the transaxle case and tighten to 7.4 N.m (66 lb in).
  193. Coat 2 new O-rings with ATF, and install them into the 2 oil cooler tube unions.
    194. Fig 135: View Of Oil Cooler Tube Unions & Transaxle Case
    GM2012196Courtesy of GENERAL MOTORS CORP.
  194. Install the 2 oil cooler tube unions to the transaxle case. Tighten the plugs to 27 N.m (20 lb ft).
  195. Coat a new O-ring with ATF, and install it to the speed sensor.
    196. Fig 136: View Of Speed Sensor & Bolt
    GM2012189Courtesy of GENERAL MOTORS CORP.
  196. Install the speed sensor to the transaxle case with the bolt. Tighten the bolt to 5.4 N.m (48 lb in).
  197. Install the park/neutral position switch assembly to the automatic transaxle.
    198. Fig 137: Locating Park/Neutral Position Switch Bolt
    GM2011858Courtesy of GENERAL MOTORS CORP.
  198. Temporarily install the 2 bolts (1, 2).
  199. Replace the lock plate with a new one and tighten the manual valve shaft nut to 6.9 N.m (61 lb in).
  200. Temporarily install the control shaft lever.
    201. Fig 138: Turning Control Shaft Lever
    GM2011914Courtesy of GENERAL MOTORS CORP.
  201. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
  202. Remove the control shaft lever.
    203. Fig 139: Aligning Groove With Neutral Base Line
    GM2011917Courtesy of GENERAL MOTORS CORP.
  203. Align the groove with the neutral base line (1).
  204. Hold the switch in this position and tighten the 2 bolts to 5.4 N.m (48 lb in).
    205. Fig 140: Staking Lock Plate Nut
    GM2011919Courtesy of GENERAL MOTORS CORP.
  205. Using a screwdriver, stake the nut with the lock plate.
    206. Fig 141: Identifying Control Shaft Lever Nut And Washer
    GM2012165Courtesy of GENERAL MOTORS CORP.
  206. Install the control shaft lever (1) with the nut and washer. Tighten the nut to 13 N.m (10 lb ft).
  207. Coat a new O-ring with ATF and install it to the speedometer driven hole cover sub-assembly.
    208. Fig 142: Locating Speedometer Driven Hole Cover Sub-Assembly Bolt
    GM2012114Courtesy of GENERAL MOTORS CORP.
  208. Install the speedometer driven hole cover subassembly (1) to the transaxle housing. Tighten the bolt to 7.0 N.m (62 lb in).
scientia non olet · About LEMON Manuals