Transaxle Reassembly

1. Install and ensure sun gear shaft, forward band, 1-2 band, reaction sun gear and reverse band drum are in place. Ensure 1-2 band anchor pins engage band, and 1-2 band assembly stop is in place.
2. Install reverse band, making sure anchor engages band. Recheck end play of final drive. See FINAL DRIVE ASSEMBLY OVERHAUL  under COMPONENT DISASSEMBLY & REASSEMBLY. Install thrust washer onto input shaft and hold it in position with petroleum jelly. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch hubs must engage clutch plates.
3. Install input clutch roller clutch and sprag assemblies into case using Final Drive/Clutch Installer (J-33381 ). DO NOT  install 2nd clutch housing, thrust bearing or thrust washer at this time.
4. Check input shaft end play. See Figure. Install and tighten Aligner/Loader (J-26958-10 ). Install End Play Gauge (J-33386 ) and thrust washer. Using feeler gauge, check clearance between thrust washer and end play gauge. Clearance must be .000-.006" (.000-.152 mm). If clearance is not as specified, use different thrust washer. See INPUT SHAFT THRUST WASHERS .
   INPUT SHAFT THRUST WASHERS
   
   

   Washer Color	Thickness: In. (mm)
   Orange/Green	.114-.118 (2.90-3.00)
   Orange/Black	.120-.124 (3.05-3.15)
   Orange	.126-.130 (3.20-3.30)
   White	.132-.136 (3.35-3.45)
   Blue	.138-.142 (3.50-3.60)
   Pink	.144-.148 (3.65-3.75)
   Brown	.150-.154 (3.80-3.90)
   Green	.155-.159 (3.95-4.05)
   Black	.161-.165 (4.10-4.20)
   Purple	.167-.171 (4.25-4.35)
   Purple/White	.173-.177 (4.40-4.50)
   Purple/Blue	.179-.183 (4.55-4.65)
   Purple/Pink	.185-.189 (4.70-4.80)
   Purple/Brown	.191-.195 (4.85-4.95)
   Purple/Green	.197-.201 (5.00-5.10)

5. Install reverse reaction plate and thrust washer. Install thrust bearing with large race facing down. Install 2nd clutch assembly onto input clutch assembly. Clutch plates must engage input clutch hub, and clutch housing must engage reverse reaction drum splines.
6. Install reverse band into case, locating band on anchor pins. Install thrust washer to driven sprocket support, and hold washer in position with petroleum jelly. Install driven sprocket support into case, ensuring support lube hole aligns with hole in bottom of case.
7. If removed, install driven sprocket support assembly. Install output shaft into case. Install "C" ring onto output shaft through bottom of case. Push "C" ring onto output shaft.
8. Coat Seal Installer (J-29569-1 and J-29829-1) with petroleum jelly, and place seal installer over turbine shaft. Slide oil ring seals into position. Using Seal Sizer (J-29569-2 and J-29829-1), size seals by gently twisting sizer over seal.
9. Install thrust washer onto drive sprocket, and hold washer in position with petroleum jelly. Install sprockets and drive link onto case. Ensure colored link faces upward.
10. Install thrust washer onto driven sprocket and retain with petroleum jelly. Insert 4th clutch shaft through driven sprocket, and install clutch apply plate with identification mark facing down. Install 4th clutch plates. See Fig 1.
    Fig 1: Aligning Channel Plate & 4th Clutch Plate

    Courtesy of GENERAL MOTORS CORP.
11. If necessary, pry out axle seal, and tap new seal into place. Install pistons and pins into channel plate. Install springs into case. Install channel plate gaskets and modulator port gasket. Install thrust washer onto channel plate.
12. Install channel plate onto case. Channel plate lugs must align with tangs on 4th clutch plates and apply plate. See Fig 1. Install sleeve into channel plate. Install oil reservoir baffle, detent spring and roller. Install channel plate gaskets.
13. Install and tighten channel plate bolts. See Fig 6. Install check balls in channel plate, using petroleum jelly to retain check balls. See Fig 2. Install converter clutch screen. Install detent spring and roller assembly.
14. Install new spacer plate/channel plate gasket onto channel plate using alignment pins. Install spacer plate onto gasket. Install new spacer plate/valve body gasket onto spacer plate. See Fig 3.
    Fig 2: Locating Channel Plate Check Balls

    Courtesy of GENERAL MOTORS CORP.
    Fig 3: Locating Channel Gaskets, Pistons & Thrust Washer

    Courtesy of GENERAL MOTORS CORP.
15. Install oil pump drive shaft and converter clutch solenoid screen. Install check balls into valve body assembly; use petroleum jelly to retain check balls in place. See Fig 4.
16. Install valve body assembly onto channel plate using alignment pins. See Fig 7. Install servo pipes into valve body using retainer and bolt.
17. Install gaskets onto case and channel plate. Install side cover. Install accumulator pins into case. Install accumulator springs into case. Larger spring is for 3-4 accumulator.
    Fig 4: Locating Valve Body Check Balls

    Courtesy of GENERAL MOTORS CORP.
18. Install lube oil pipe retainer spring into pocket. Install lube oil pipe retainer onto lube oil pipe and "O" ring onto retainer. Install lube oil pipe into case. Ensure pipe is installed into driven sprocket support lube hole.
19. Install spacer plate and new gaskets onto case. Install oil scavenger scoop. Install wiring. Install accumulator cover, pipes and retainer onto case as an assembly.
20. Ensure lube oil pipe is installed into final drive internal gear. Install new filter lip seal, filter and gasket into case. Install pan.
21. Install 1-2 and reverse servo return springs into proper servo bore. Assemble each servo and then install into case. Install new oil seal ring onto each servo cover. Install 1-2 and reverse servo covers into case. Install snap rings.
22. Install speed sensor. Install modulator valve into case. Install new "O" ring seal onto modulator. Install modulator into case. Install retainer and bolt. Use Converter Holding Strap (J-21366) to hold torque converter in place for installation.