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Home >> Saturn >> 2000 >> LS1 Automatic >> Repair and Diagnosis (Single Page) >> Transmission >> Automatic Trans >> Automatic Transaxle Overhaul & Testing - 4T40-E & 4T45-E >> Component Disassembly, Reassembly & Transaxle Reassembly >> Coast & Direct Clutch, & Reaction Carrier Assembly >> Reassembly

Coast & Direct Clutch, & Reaction Carrier Assembly: Reassembly

  1. Lubricate coast clutch piston seal with transaxle fluid prior to installation. Install coast clutch piston assembly into input housing. Install coast clutch release spring and spring retainer into input housing. See Figure . Spring retainer must be assembled with inner lip facing up.
  2. Using Clutch Spring Compressor (J-23327) and Adapter (J-41236), compress coast clutch spring retainer and install snap ring onto input housing. Remove spring compressor and adapter. Lubricate direct clutch piston seal with transaxle fluid. Install direct clutch piston assembly into input housing.
  3. Install direct clutch spring and retainer assembly into input housing with snap ring tabs facing up. Using clutch spring compressor and Adapter (J-41232), compress direct clutch spring and retainer assembly and install snap ring into input housing. See Figure . Remove spring compressor and adapter.
  4. Install coast clutch plates into input housing. Start with steel plate and alternate between 4 steel and 4 NEW friction plates. Steel plates must be assembled with splines in input housing grooves that are machined to piston.
  5. Place sprag outer race on bench with flat side down and end with snap ring groove up. Place one end bearing into outer race. Install sprag clutch into sprag outer race with grooved edge up and flat side down. Rotate sprag slowly during assembly. Install other end bearing on top of sprag clutch.
  6. Install snap ring into sprag outer race to retain sprag assembly and end bearings. Install sprag clutch and outer race assembly onto input sun gear shaft. Snap ring side of assembly faces up when installing sprag clutch onto input sun gear shaft. Flat side of sprag outer race functions as backing plate for coast clutch. Rotate input sun gear shaft clockwise during assembly to help seat sprags.
  7. Ensure correct operation of sprag clutch by holding sprag clutch outer race and rotating input sun gear shaft. Input sun gear shaft should only rotate in clockwise direction. See Fig 1 .
    Fig 1: Checking Sprag Clutch Operation
    G96J04031Courtesy of GENERAL MOTORS CORP.
  8. Coat thrust bearing with petroleum jelly. Install thrust bearing on back side of input sun gear shaft. Install input sun gear shaft and sprag clutch assembly into input housing. Splines on input sun gear shaft engage with coast clutch friction plates.
  9. Install direct clutch plates into input housing. Start with steel plate and alternate between steel plate and NEW friction plates. Ensure same number of steel and friction plates removed are reinstalled. Install direct clutch backing plate onto input housing with flat side down.
  10. Install snap ring to retain input sun gear shaft, sprag clutch assembly and direct clutch plates. Coat thrust bearing with petroleum jelly. Install thrust bearing on top of sprag clutch assembly. Install reaction carrier shaft shell onto input housing. Splines on inside of reaction carrier shaft shell engage direct clutch friction plates.
  11. Install thrust bearing onto top of reaction carrier shaft shell. Install reaction sun shell onto reaction carrier shaft shell. Install reaction carrier assembly onto reaction sun gear. Rotate reaction carrier assembly to mesh sun gear with pinion gears.
  12. Install reaction carrier assembly-to-input sun gear thrust bearing onto reaction carrier assembly. Install input sun gear onto input sun gear shaft. Install input sun gear snap ring onto input sun gear shaft.
  13. Slide Seal Guide (J-41234-1) over input shaft and position at seal groove closest to housing. See Fig 2 . Coat seal guide with transaxle fluid. Guide NEW Teflon seal onto seal guide and slide seal into groove using Seal Installer (J-41234-2). Repeat procedure for 3 remaining seals, adjusting seal guide as necessary.
    Fig 2: Installing Input Shaft Teflon Seal Rings
    G96B04032Courtesy of GENERAL MOTORS CORP.
  14. After all seals are installed, use Seal Sizer (J-41234-3) to size seals. Leave tool in place for at least 5 minutes. If possible, leave tool in place until assembly is ready to be installed in transaxle case.
  15. Air check coast clutch and direct clutch to ensure proper operation of seals and clutch assemblies. Apply 20 psi (1.41 kg/cm2 ) of compressed air to specified location to check component operation. See Fig 3 . If clutch assemblies do not operate properly, check component installation.
    Fig 3: Checking Coast & Direct Clutch Operation
    G96D04033Courtesy of GENERAL MOTORS CORP.
  16. Install coast clutch, direct clutch and reaction carrier assembly into transaxle case. Measure clutch assembly end play. Place gauge block across machined surface of transaxle case. See Fig 4 . Measure distance between top of coast and direct clutch housing and machined surface of transaxle case (Dimension "A"). Choose correct selective thrust washer. See SELECTIVE THRUST WASHER IDENTIFICATION  table.
    Fig 4: Measuring Clutch Assembly End Play
    G96F04034Courtesy of GENERAL MOTORS CORP.
  17. Install selective thrust washer on top of input housing. Tab on thrust washer must be located in recessed area for retainer and ball assembly. Install thrust bearing over input shaft and on top of selective thrust washer.
SELECTIVE THRUST WASHER IDENTIFICATION

Dimension "A" - In. (mm) Washer Identification Washer Thickness - In. (mm)
3.95-3.96 (100.4-100.6) Brown .059-.062 (1.50-1.60)
3.96-3.98 (100.6-101.1) Gray .070-.075 (1.78-1.91)
3.98-3.99 (101.1-101.4) Natural .082-.086 (2.08-2.18)
3.99-4.00 (101.4-101.6) Black .094-.098 (2.39-2.49)
4.00-4.01 (101.6-101.9) Orange .106-.109 (2.69-2.77)
4.01-4.02 (101.9-102.1) Violet .117-.121 (2.97-3.07)
4.02-4.03 (102.1-102.4) Yellow .129-.133 (3.28-3.38)
4.03-4.05 (102.4-102.9) Red .141-.145 (3.58-3.68)
4.05-4.06 (102.9-103.1) Green .152-.156 (3.86-3.96)
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