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Transaxle Reassembly

NOTE: Note location of all gear sets, clutch plates, thrust bearings, thrust washers and bushings. See Fig 1 and Fig 2 . Recheck snap ring and thrust washer measurements taken during disassembly. See appropriate procedures under TRANSAXLE DISASSEMBLY  .
Fig 1: Locating Thrust Bearing, Thrust Washer & Bushing
G92I12698Courtesy of GENERAL MOTORS CORP.
Fig 2: Exploded View of Gear Sets & Clutch Plates
G92H12697Courtesy of GENERAL MOTORS CORP.
LEGEND FOR FIGURE 38

Item No. Component
1 Driven Sprocket Support Bearing
2 Driven Sprocket Support Sleeve
3 Driven Sprocket Support Assembly
4 Driven Sprocket Support Bushing
5 Driven Sprocket Support Ring Oil Seals
6 Driven Sprocket Support-To-Washer
7 Band Anchor Hole Plug
8 Intermediate Band
9 Direct Clutch Housing Bushing
10 Direct Clutch Housing & Drum
11 Direct Clutch Check Valve Retainer & Ball Assembly
12 Direct Clutch Drum Bushing
13 Direct Clutch Piston Outer Lip Seal
14 Direct Clutch Center Lip Seal
15 Direct Clutch Piston Inner Lip Seal
16 Direct Clutch Piston
17 Apply Ring & Release Spring Assembly
18 Snap Ring
19 Direct Clutch Plate Assembly
20 Direct Clutch Backing Plate
21 Snap Ring
22 Selective Input Shaft Snap Ring
23 Input Shaft Seal Rings
24 Input Shaft Bushing
25 Forward Clutch Housing Assembly
26 Forward Clutch Piston Outer Lip Seal
27 Forward Clutch Piston Inner Lip Seal
28 Forward Clutch Piston Insert
29 Forward Clutch Piston
30 Forward Clutch Release Spring Guide
31 Forward Clutch Retainer & Spring Assembly
32 Forward Clutch Snap Spring Retainer Ring
33 Forward Clutch Waved Plate
34 Forward Clutch Plate Assembly
35 Forward Clutch Waved Plate
36 Forward Clutch Backing Selective Plate
37 Snap Ring
38 Input Shaft Thrust Washer
39 Input Internal Gear
40 Input Internal Gear Bushing
41 Input Carrier/Input Internal Gear Tanged Thrust Washer
42 Input Carrier Assembly
43 Input Carrier/Input Sun Gear Tanged Thrust Washer
44 Input Sun Gear
45 Input Drum
46 Selective Input Drum/Sun Gear Snap Ring
47 Reaction Sun Gear Bushing
48 Reaction Sun Gear
49 Case Splines Snap Ring (Thick)
50 Reaction Carrier Bushing
51 Low-Reverse Clutch Housing Assembly
52 Low-Reverse Piston Outer Lip Seal
53 Low-Reverse Piston Inner Lip Seal
54 Low-Reverse Clutch Piston
55 Low-Reverse Clutch Release Spring
56 Low-Reverse Clutch Spring Retainer
57 Low-Reverse Piston Snap Ring
58 Case Splines Snap Ring (Thin)
59 Low-Reverse Clutch Waved Plate
60 Low-Reverse Clutch Plate Assembly
61 Low-Reverse Clutch Waved Plate
62 Low-Reverse Clutch Backing Selective Plate
63 Reverse Housing/Low Roller Race Selective Spacer
64 Low Roller Clutch Race
65 Low Roller Clutch Roller Assembly
66 Reaction Carrier/Low Roller Race Thrust Washer
67 Reaction Carrier Bushing
68 Reaction Carrier Assembly
69 Reaction Carrier/Reaction Internal Gear 4-Tanged Thrust Washer
70 Reaction Sun/Reaction Internal Gear Thrust Bearing
71 Reaction Internal Gear
72 Final Drive Sun Gear Shaft
73 Case Splines Snap Ring (Thick)
74 Final Drive Internal Gear Spacer
75 Final Drive Internal Gear Bushing
76 Final Drive Internal Gear
77 Thrust Sun Gear/Final Drive Internal Gear Bearing
78 Final Drive Sun Gear
79 Thrust Sun Gear/Differential Carrier Bearing
80 Spiral Pinion Retainer Ring
81 Carrier Assembly Differential
82 Governor Drive Gear
83 Selective Differential Carrier/Case Thrust Washer
84 Differential Carrier/Case Thrust Bearing Assembly
85 Differential Pinion Shaft
86 Differential Pinion Shaft Retainer Pin
87 Differential Pinion Thrust Washer
88 Differential Pinion
89 Differential Side Gear Thrust Washer
90 Differential Side Gear
91 Pinion Thrust Washer *  Bronze (Steel For Replacement)
92 Pinion Thrust Washer (Steel)
93 Needle Bearing Roller
94 Pinion Needle Bearing
95 Final Drive Planetary Pinion
96 Planetary Pinion Pin
  1. Lubricate all bushings, seals, thrust bearings and internal mating surfaces with transmission fluid during reassembly. Use petroleum jelly to hold thrust washers in place.
  2. Install selected differential carrier/case thrust washer. See Figure . Install thrust bearing assembly to final drive unit (inner race of bearing against selective washer). Install differential and final drive assembly into case.
  3. Install final drive internal gear spacer (cupped side against final drive internal gear). Ensure opening in spacer aligns with parking pawl opening in case. Ensure parking pawl passes through spacer.
  4. Install final drive spacer-to-case snap ring with ring gap away from parking pawl opening in case. Install reaction sun gear set into case. See Figure .
  5. Install low-reverse clutch backing plate (stepped side down) and clutch plates into case. See Figure . Start with a composition plate, and then alternate between steel and composition plates.
  6. Install low-reverse clutch wave plate and thin housing-to-case spacer ring. Install low-reverse clutch housing assembly into transaxle case. See Figure . Ensure clutch feed hole in housing lines up with clutch feed hole in case.
  7. Install selective snap ring onto reaction sun gear. Install reaction sun gear onto final drive sun gear shaft in transaxle. See Figure and Figure . Rotate reaction sun gear while pushing down on low-reverse clutch housing until clutch housing drops below snap ring groove in case.
  8. Install thick low-reverse clutch housing-to-case snap ring. See Figure . Install input drum onto reaction sun gear. See Figure . Install input sun gear into input drum. Install input sun gear tanged thrust washer to pinion side of carrier.
  9. Install input internal gear tanged thrust washer to internal gear side of carrier (input internal gear tanged thrust washer is larger than input sun gear tanged thrust washer). See Figure . Install input pinion carrier onto input sun gear.
  10. Install input internal gear over input carrier. Place forward clutch assembly on bench with input shaft up. Install direct clutch assembly over input shaft, onto forward clutch housing. When clutch housings are fully seated, distance from tang end of direct clutch housing to end of forward clutch housing should be 1.406" (35.71 mm). See Fig 3 .
    Fig 3: Measuring Forward Clutch-to-Direct Clutch Height
    G92C12700Courtesy of GENERAL MOTORS CORP.
  11. Install input shaft-to-input internal gear thrust washer onto forward and direct clutch assembly. See Figure and Fig 1 . Ensure rounded side is against input shaft, and stepped side faces outward, onto forward and direct clutch assembly.
  12. Install direct and forward clutch assemblies into case. Rotate clutch assemblies, without pushing down, until they drop into fully seated position in case. When correctly installed, case face-to-direct clutch housing distance should be 1 1/6". See Fig 4 .
    Fig 4: Installed Position of Direct & Forward Clutch
    G92D12701Courtesy of GENERAL MOTORS CORP.
  13. Install intermediate band. Install band anchor hole plug. Install driven sprocket support-to-direct clutch housing thrust washer. Install driven sprocket support. See Figure .
  14. Install manual shaft and parking lock actuator rod into case through driven sprocket support. Install detent lever on manual shaft (hub side away from driven sprocket support), and push manual shaft in place. Install detent lever-to-manual shaft retaining pin. Install manual shaft-to-case retaining nail. See Figure .
  15. Assemble drive and driven sprockets with link assembly, and install drive and driven thrust washers to sprockets. Install drive link assembly onto transaxle. See Figure . The colored guide link must face case cover.
  16. Install case cover-to-driven sprocket roller bearing thrust washer (outer race against sprocket). Install 1-2 accumulator piston. Install thermostatic spring (if removed). See CONTROL VALVE BODY & OIL PUMP ASSEMBLIES  under COMPONENT DISASSEMBLY & REASSEMBLY.
  17. Install 1-2 accumulator spring into bore in case. Install inner and outer case-to-cover gaskets and case cover. Install and tighten all case cover bolts. See Fig 5 . Install 2 case cover bolts from inside torque converter housing (M8 x 1.25 x 14 mm). Install remaining case cover bolts. The 3 bolts that mate sprocket support-to-case cover must be tightened evenly to avoid cocking sprocket support.
  18. Connect manual valve rod to manual valve. Install check balls No. 2-6 into case cover. See Figure .
  19. Install No. 1 check ball on direct clutch passage on spacer plate. Install oil pump shaft into bore in case cover. Install 2 guide pins (M6 x 1.0 x 75 mm) in case cover-to-valve body bolt holes.
  20. Install control valve body and along with bolts and tighten. See Fig 6 . Install valve body wiring harness. See GM TORQUE CONVERTER CLUTCH article in AUTOMATIC TRANSMISSIONS article for information on converter clutch system. Connect lever link to T.V. bracket. Install T.V. bracket onto valve body.
  21. Remove guide bolts used to install valve body, and install remaining 2 valve body bolts. Thoroughly clean valve body cover. Install cover with new gasket. Apply Loctite sealant to indicated cover bolts. See Fig 7 .
    Fig 5: Locating Case Cover Bolts
    G92E12702Courtesy of GENERAL MOTORS CORP.
    Fig 6: Locating Control Valve Body Bolts
    G92F12703Courtesy of GENERAL MOTORS CORP.
    Fig 7: Applying Sealant to Case Cover & Oil Pan Bolts
    G92G12704Courtesy of GENERAL MOTORS CORP.
  22. Turn transaxle so oil pan side is up. Install output shaft into transaxle. See Figure . Rotate final drive so retaining ring groove is visible through access window in case. Install new retaining ring onto shaft groove.
  23. Install parking lock bracket and dipstick stop. Using a 3/8" drift, install new low-reverse oil pipe seal assembly. Install "O" ring backup washer and "O" ring seal onto end of low-reverse pipe. Install pipe and retainer bracket.
  24. Install intermediate servo piston assembly. Use new inner and outer oil seals on piston and new seal on apply pin (apply pin size was determined during transaxle disassembly procedure). Install 3rd accumulator exhaust valve and spring into check valve bore next to servo piston. Install intermediate servo cover and 3 bolts. See Figure .
  25. Install reverse oil pipe bracket to oil pipe and servo cover. Install remaining servo cover bolt through bracket and cover. Tighten servo cover bolts. Install new oil strainer and "O" ring. Install oil pan gasket and oil pan. Apply Loctite sealant to oil pan bolt threads. See Fig 7 . Rotate transaxle so oil pan side is down. Install governor assembly. Install new "O" ring to governor cover, and install cover onto case. Install speedometer/speed sensor driven gear assembly into governor cover.
  26. Ensure governor shaft is piloted in governor cover before tightening cover bolts. Install torque converter.
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