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Home >> Saturn >> 2006 >> Vue Red Line, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 15 (Automatic Transaxle - 4T45-E - Overhaul) >> Off-Vehicle Repair Instructions >> Direct/Coast Clutch, Reaction Carrier Assemble

Direct/Coast Clutch, Reaction Carrier Assemble

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Locating Coast Clutch Piston And Seal Assembly
    GM20279Courtesy of GENERAL MOTORS CORP.
  1. In order to aid in the assembly, lubricate the seal with transmission fluid.
  2. Assemble the coast clutch piston and seal assembly (504) into the input housing (502).
    3. IMPORTANT: You must assemble the spring retainer with the inner lip facing up.
  3. Assemble the coast clutch release spring (505) and spring retainer (506) into the input housing (502).
    4. Fig 2: Locating Coast Clutch Spring Retainer Snap Ring
    GM20268Courtesy of GENERAL MOTORS CORP.
  4. Compress the coast clutch return spring retainer (506). Use the J 41236  and J 23327  or equivalent. See Special Tools .
  5. Assemble the coast clutch spring retainer snap ring (507) onto the input housing (502).
  6. Remove the J 41236  and J 23327  . See Special Tools .
    7. Fig 3: Identifying Direct Clutch Return Spring Assembly
    GM20267Courtesy of GENERAL MOTORS CORP.
  7. In order to aid in the assembly, lubricate the seal with transmission fluid.
  8. Assemble the direct clutch piston and seal assembly (518) into the input housing (502).
  9. Assemble the direct clutch return spring assembly (519) into the input housing with the snap ring retaining tabs facing up.
    10. Fig 4: View Of Direct Clutch Snap Ring
    GM20266Courtesy of GENERAL MOTORS CORP.
  10. Compress the direct clutch spring assembly. Use the J 41232  and J 23327  or equivalent. See Special Tools .
  11. Assemble the direct clutch snap ring (520) into the input housing (502).
  12. Remove the J 41232  and J 23327  . See Special Tools .
    13. Fig 5: Identifying Coast Clutch Plates
    GM20265Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Assemble the steel plates (508) with the splines in the input housing grooves that are machined to the pistons.
  13. Assemble the 4 steel coast clutch plates (508) and the 4 new fiber coast clutch plates (509) into the input housing in alternating order, beginning with a steel plate (508).
    14. Fig 6: Input Sun Gear Shaft
    GM1644750Courtesy of GENERAL MOTORS CORP.
  14. Place the sprag outer race (512) on the bench with the flat side down and the side with the snap ring groove up.
  15. Place one end bearing (514) into the outer race.
  16. While rotating the sprag slowly, assemble the sprag clutch (515) into the sprag outer race. Keep the four notches up and the flat side down.
  17. Assemble the other end bearing (514) on top of the sprag clutch.
  18. Assemble the snap ring (516) into the sprag outer race (512) in order to retain the sprag clutch and end bearings.
    19. IMPORTANT: The snap ring side of the assembly faces up when installing the sprag clutch onto the input sun gear shaft. The flat side of the sprag outer race functions as the backing plate for the coast clutch.
  19. While rotating the input sun gear shaft clockwise in order to help seat the sprags, assemble the sprag clutch and outer race assembly onto the input sun gear shaft (511).
    20. Fig 7: Checking Input Sun Gear Shaft Rotation
    GM20283Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The input sun gear shaft (511) must only rotate clockwise.
  20. Verify the correct operation of the sprag clutch by holding the sprag clutch outer race (512) and rotating the input sun gear shaft (511).
    21. Fig 8: Locating Thrust Bearing On Input Sun Gear Shaft
    GM20264Courtesy of GENERAL MOTORS CORP.
  21. Assemble the thrust bearing (510) on the underside of the input sun gear shaft.
  22. Retain the thrust bearing with J 36850  or equivalent.
  23. Assemble the input sun gear shaft and sprag clutch assembly (511 and 512) into the input housing. The splines on the input sun gear shaft engage with the coast clutch fiber plates.
    24. Fig 9: Identifying Direct Coast Clutch Plates
    GM20261Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Direct clutch plates are model dependent. Refer to Clutch Plate Selection Specifications  to determine correct plate quantity. Then refer to either the above illustration for 6 plate or the following illustration for 5 plate installation sequence.
  24. Assemble the 6 steel (521) and 6 new fiber 522) direct clutch plates into the input housing in alternating order beginning with a steel plate (521).
  25. Assemble the direct clutch backing plate (523) onto the input housing with the flat side down.
  26. Assemble the snap ring (517) in order to retain the input sun shaft and sprag clutch assembly and the direct clutch plates.
    27. Fig 10: Direct Clutch Plates
    GM1658216Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Direct clutch plates are model dependent. Refer to Clutch Plate Selection Specifications  to determine correct plate quantity. Then refer to either of the above illustration for 6 plate or 5 plate installation sequence.
  27. Assemble the 7 steel (521) and 5 new fiber 522) direct clutch plates into the input housing in alternating order beginning with a steel plate (521). Note the location of the 4th and 5th fiber plates. 3 steel plates will be installed together.
  28. Assemble the direct clutch backing plate (523) onto the input housing with the flat side down.
  29. Assemble the snap ring (517) in order to retain the input sun shaft and sprag clutch assembly and the direct clutch plates.
    30. Fig 11: Reaction Carrier Shaft & Shell Assembly And Thrust Bearing
    GM20260Courtesy of GENERAL MOTORS CORP.
  30. Assemble the thrust bearing (524) on the top of the sprag clutch assembly. Retain with J 36850  or equivalent.
  31. Assemble the reaction carrier shaft and shell assembly (526) onto the input housing. The splines on the inside of the shell engage the direct clutch fiber plates.
    32. Fig 12: Locating Thrust Bearing On Top Of Reaction Carrier Shaft
    GM20259Courtesy of GENERAL MOTORS CORP.
  32. Assemble the thrust bearing (527) onto the top of the reaction carrier shaft and shell assembly.
  33. Assemble the reaction carrier sun gear and shell assembly (529) onto the reaction shaft shell.
    34. IMPORTANT: Rotate the reaction carrier during assembly in order to mesh the sun gear with the pinion gears.
  34. Assemble the reaction carrier assembly (531) onto the reaction sun gear.
    35. Fig 13: View Of Reaction Carrier Assembly To Input Sun Gear Thrust Bearing
    GM20258Courtesy of GENERAL MOTORS CORP.
  35. Assemble the reaction carrier assembly to input sun gear thrust bearing (532) onto the reaction carrier assembly.
  36. Assemble the input sun gear (533) onto the input sun gear shaft.
  37. Assemble the input sun gear snap ring (534) onto the input sun gear shaft.
    38. Fig 14: Assembling Seals On Input Shaft
    GM20284Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When assembling the four new Teflon seals (500) onto the input shaft, begin with the seal closest to the housing.
  38. Slide the J 41234-2  over the input shaft, and position the J 41234-2  at the seal groove closest to the housing. See Special Tools . Coat the J 41234-2  with transmission fluid. See Special Tools .
  39. Guide a new seal onto the J 41234-2  and slide the seal into the seal groove with the J 41234-1  . See Special Tools .
  40. Repeat the above procedure for each seal. Adjust the J 41234-2  as necessary for each seal groove. See Special Tools .
    41. Fig 15: Sizing Seals With J 41234-3
    GM20841Courtesy of GENERAL MOTORS CORP.
  41. Size the seals with the J 41234-3  . See Special Tools .
  42. Leave the J 41234-3  in place for at least five minutes. See Special Tools . If possible, leave the J 41234-3  in place until you install the assembly (105) into the transmission case. See Special Tools .
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