Transaxle Reassembly
NOTE:
All selective snap ring and thrust washer measurements taken during disassembly must be rechecked at appropriate reassembly stage. See Fig 10
for thrust washer and thrust bearing locations. See Fig 11
for seal location and identification.
- Install manual shaft, detent lever assembly and parking pawl, if removed. See Figure . Install drive sprocket support, input speed sensor and wiring harness. See Figure . Install torque converter seal.
- Install lo/reverse band and ensure anchor engages band. Install support fretting ring with open end toward lower oil pan. Install oil cooler return fitting "O" ring to coast and forward clutch assembly. Using Forward/Coast Clutch Puller (J-39053), install coast and forward clutch assembly into case. See Figure . Ensure anchor holes in support align with holes in case.
- Install final drive internal gear with groove up. Install snap ring with flat side down and open end in actuator rod area. Rotate support counterclockwise against spline. See Fig 1 .
- Install reaction carrier shell into forward clutch housing with small teeth facing down. Install 3rd clutch housing and reaction carrier assembly. Install input shaft selective thrust washer and thrust bearing on 3rd clutch housing. See Figure
. Install 4th band and reverse clutch assembly. See Fig 2
. Ensure band pin seat engages servo pin. Install reverse clutch housing and thrust washer.
Courtesy of GENERAL MOTORS CORP.
- Install seal on drive sprocket support. Using Sizer (J-39064-2), size seal. Install backing plate, 2nd clutch plates, apply plate and wave plate. See Figure .
- Place scavenge tube seal on driven sprocket support and install driven sprocket support. Install drive chain (in same direction as removed) to drive sprocket support. Tap sprockets until seated. Place thrust washers on sprockets.
- To air check reverse, 2nd and 3rd clutches at drive sprocket support, go to next step. Install island gasket and case cover gasket. See Fig 4 . Install case cover allowing wiring harness connector to pass through opening in case cover. Install bolts in correct position and hand tighten only. Go to step 10 .
- Using 50-60 psi (2.7 kg/cm2 ) of air pressure, air check clutch assemblies. Reverse, 2nd and 3rd clutches may be checked at driven sprocket support. Coast and forward clutches may be checked through passage in lower case. See Fig 5 . To check 4th servo, fabricate an air checking plate. See Fig 6 .
- Trace template as shown. See Fig 6 . Using 3/8-1/2" thick aluminum or plastic plate, cut out an air checking plate to match template. Mark and drill holes in plate. Drill bolt holes .275" (7 mm) and air holes .157" (4 mm). Bolt plate to case. Air check 4th servo. Reverse clutch and 2nd clutch can be air checked using plate.
- Check input shaft end play. See Figure . Install Input Shaft End Play Fixture (J-39686) to front side of transaxle. Ensure "J" tab on fixture rests on input shaft. Mount Dial Indicator Post (J-25025-7A) and Dial Indicator (J-8001-3) to check end play. Push down on handle. End play should be .004-.033" (.10-.85 mm). Input shaft thrust washers size range is .089-.195" (2.26-4.95 mm) in increments of .012" (.30 mm).
- Tighten case cover bolts and studs in a crisscross pattern. Install 2 check balls. See Fig 4 . Install upper valve body. See Fig 7 . Tighten bolts starting with center bolts and working to outside bolts. Install side filter.
- Install TCC solenoid and transaxle pressure control solenoid. Install oil pump assembly. Tighten bolts starting with center bolts and working to outside bolts. Install oil pan and tighten bolts in a star pattern. Install 4th servo. See Fig 3 . Ensure tab on servo piston aligns with slot in case (some models).
- Ensure lo/reverse band is installed in correct position. Install lower valve body and channel plate. See Fig 8 . Install bolts and tighten by hand. Remove shim stock.
- Install oil transfer plate and hand tighten bolts. See Fig 8 . Connect wiring harness and manual valve. Tighten channel plate and oil transfer plate bolts in a crisscross pattern. Install scavenge screens. See Fig 3 . Install lower oil pan and gasket and tighten bolts to specification in correct sequence. See Fig 9 .
- Assemble and install final drive, output shaft and differential carrier. Engage parking pawl to hold final drive unit. Tighten differential carrier bolts.
- Install scavenge tube and seal. See Fig 3 . Install selective thrust washer and roller thrust bearing onto output shaft. Install extension housing and hand tighten bolts.
- Use Dial Indicator Post (J-25025-7A) and Dial Indicator (J-8001-3) to check end play. Pry up on speed sensor rotor through speed sensor hole. End play should be .006-.026" (.15-.65 mm). See Figure .
- If necessary, adjust end play with selective final drive-to-case thrust washer. See FINAL DRIVE-TO-CASE SELECTIVE THRUST WASHER SIZES table. Tighten extension housing bolts. Install oil cooler return fitting to forward and coast clutch support. Install axle seals, oil pump drive shaft, torque converter and vehicle speed sensor.
CAUTION:
Forward/Coast clutch assembly weighs 50 pounds. Ensure appropriate lifting equipment is used to install clutch assemblies.
FINAL DRIVE-TO-CASE SELECTIVE THRUST WASHER SIZES
| Thrust Washer Identification Color | Thickness - In. (mm) |
|---|---|
| Orange | .137-.141 (3.48-3.58) |
| White | .131-.136 (3.33-3.45) |
| Blue | .126-.130 (3.20-3.30) |
| Pink | .120-.125 (3.05-3.18) |
| Brown | .115-.119 (2.92-3.02) |
| Green | .110-.114 (2.79-2.90) |
| Black | .104-.109 (2.64-2.77) |