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Home › Saturn › 2004 › Vue Red Line, AWD › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transmission, 5AT (Introduction) › Specifications › Transmission Clearance Specifications

Transmission Clearance Specifications

Clutch

Application Standard or New Service Limit
Metric English Metric English
Clutch Backing-Plate-to-Top-Disc Clearance
  • 1st Clutch
 - 1.1-1.3 mm 0.043-0.051 in
  • 2nd Clutch
 - 1.0-1.2 mm 0.039-0.047 in
  • 3rd Clutch
 - 0.7-0.9 mm 0.028-0.035 in
  • 4th, 5th Clutch
 - 0.55-0.75 mm 0.022-0.030 in
  • 1st-Hold Clutch
 - 0.6-1.0 mm 0.024-0.039 in
Clutch Plate Thickness
  • 1st Clutch
 1.6 mm 0.06 in When discolored
  • 2nd Clutch
 1.8 mm 0.07 in When discolored
  • 3rd, 4th, 5th Clutch
 2.0 mm 0.079 in When discolored
  • 1st-Hold Clutch
 1.8 mm 0.07 in When discolored
Clutch Return Spring Free Length
  • 1st Clutch
 68.3 mm 2.69 in 66.3 mm 2.61 in
  • 2nd Clutch
 48.3 mm 1.90 in 46.3 mm 1.82 in
  • 3rd Clutch
 52.0 mm 2.05 in 50.0 mm 1.97 in
  • 4th Clutch
 37.7 mm 1.48 in 35.7 mm 1.41 in
  • 5th Clutch
 37.4 mm 1.47 in 35.4 mm 1.39 in
Stator Shaft (404)

Application Standard or New Service Limit
Metric English Metric English
I.D. at Mainshaft Sealing Ring Contact Area 31.000-31.025 mm 1.220-1.221 in 31.05 mm 1.222 in
I.D. at Needle Bearing Contact Area
  • Automatic Transmission Fluid Pump Side
 31.000-31.025 mm 1.220-1.221 in -
  • Torque Converter Side
 27.000-27.021 mm 1.063-1.064 in When worn or damaged
Reverse Shift Fork (924)

Application Standard or New Service Limit
Metric English Metric English
Reverse Shift Fork 5.90-6.00 mm 0.220-0.236 in 5.4 mm 0.213 in
Regulator Valve Body (422)

Application Standard or New Service Limit
Metric English Metric English
Mainshaft Sealing Ring Contact I.D. 31.000-31.025 mm 1.220-1.221 in 31.05 mm 1.222 in
Shift Fork Shaft Bore I.D. 14.000-14.010 mm 0.5512-0.5516 in -
Shift Fork Shaft/Secondary Valve 37.000-37.039 mm 1.4567-1.4582 in 37.045 mm 1.4585 in
Main Control Valve Body (203)

Application Standard or New Service Limit
Metric English Metric English
Third Shaft Sealing Ring Contact I.D. 35.000-35.025 mm 1.3780-1.3789 in 35.05 mm 1.3799 in
1st/2nd Clutch Shaft, Apply Fluid Collar (129)

Application Standard or New Service Limit
Metric English Metric English
1st/2nd Clutch Shaft Sealing Ring Contact 29.000-29.021 mm 1.1417-1.1426 in 29.05 mm 1.1437 in
Mainshaft (640)

Application Standard or New Service Limit
Metric English Metric English
5th Gear Axial Clearance 0.10-0.22 mm 0.004-0.009 in -
5th Gear Collar Diameter at Needle Bearing Contact Area 39.975-39.991 mm 1.5738-1.5744 in When worn or damaged
5th Gear Collar Flange Thickness 5.15-5.30 mm 0.203-0.209 in When worn or damaged
5th Gear Collar Length 48.7-48.8 mm 1.917-1.921 in -
5th Gear I.D. 46.000-46.016 mm 1.8110-1.8116 in When worn or damaged
Diameter at Stator Shaft Needle Bearing Contact Area 22.984-23.000 mm 0.9049-0.9055 in When worn or damaged
Sealing Ring Groove Width 2.025-2.060 mm 0.080-0.081 in 2.08 mm 0.082 in
Sealing Ring Thickness 1.90-1.96 mm 0.074-0.077 in 1.85 mm 0.073 in
Output Shaft (535)

Application Standard or New Service Limit
Metric English Metric English
Axial Clearance of Gears
  • 2nd Driven Gear
 0.005-0.040 mm 0.0002-0.0016 in -
  • 5th Driven Gear
 0.12-0.27 mm 0.0047-0.0106 in -
  • 1st/2nd Idler Gear
 0.005-0.040 mm 0.0002-0.0016 in -
  • Reverse Driven Gear
 0.10-0.25 mm 0.0039-0.0098 in -
Cotter Thickness 1.99-2.02 mm 0.078-0.080 in -
Diameter at Bearing Contact Area
  • 5th gear
 34.975-34.991 mm 1.3770-1.3776 in When worn or damaged
  • Torque Converter Housing Bearing
 40.505-40.515 mm 1.5947-1.5951 in When worn or damaged
Diameter of 2nd Gear at Needle Bearing Contact Area 56.975-56.991 mm 2.2431-2.2437 in When worn or damaged
I.D of Gears
  • 5th Gear
 41.000-41.0016 mm 1.6142-1.6148 in When worn or damaged
  • Idler Gear
 65.000-65.019 mm 2.5590-2.5598 in When worn or damaged
  • Reverse Gear
 46.000-46.016 mm 1.8110-1.8116 in When worn or damaged
Reverse Gear Collar O.D. 39.979-40.000 mm 1.5740-1.5748 in When worn or damaged
Reverse Selector Hub O.D. 55.885-55.900 mm 2.200-2.201 in When worn or damaged
Thrust Washer Thickness - 35 x 47 mm 5.97-6.00 mm 0.2350-0.2362 in When worn or damaged
1st/2nd Clutch Shaft (755)

Application Standard or New Service Limit
Metric English Metric English
1st Gear Collar Length 63.3-63.4 mm 2.4921-2.4961 in -
ATF Feed Pipe O.D.
  • 1st Clutch
 11.47-11.48 mm 0.4516-0.4520 in 11.45 mm 0.4508 in
  • 1st Hold Clutch
 5.97-5.98 mm 0.2350-0.2354 in 5.95 mm 0.2343 in
Axial Clearance of Gears
  • 1st Drive Gear
 0.085-0.130 mm 0.0033-0.0051 in -
  • 2nd Gear
 0.06-0.23 mm 0.0024-0.0091 in -
Diameter at Bearing Contact Area
  • 2nd gear
 43.986-43.999 mm 1.7317-1.7322 in When worn or damaged
  • Torque Converter Housing Bearing
 32.002-32.015 mm 1.2599-1.2604 in When worn or damaged
  • Torque Converter Housing Bearing - Shaft End Side
 28.592-28.608 mm 1.1257-1.1263 in When worn or damaged
Diameter of 1st Gear Collar at Needle Bearing Contact Area 38.975-38.991 mm 1.5344-1.5351 in When worn or damaged
Feed Pipe Bushing I.D.
  • 1st Clutch
 11.518-11.530 mm 0.4535-0.4539 in 11.545 mm 0.4545 in
  • 1st Hold Clutch
 6.018-6.030 mm 0.2369-0.2374 in 6.045 mm 0.2380 in
I.D. of Gears
  • 1st Gear
 44.000-44.016 mm 1.7323-1.7329 in When worn or damaged
  • 2nd Gear
 50.00-50.02 mm 1.9685-1.9693 in When worn or damaged
Sealing Ring Groove Width 2.025-2.060 mm 0.080-0.081 in 2.08 mm 0.082 in
Sealing Ring Thickness 1.91-1.97 mm 0.075-0.078 in 1.86 mm 0.073 in
3rd Clutch Shaft (830)

Application Standard or New Service Limit
Metric English Metric English
Axial Clearance of 3rd Gear 0.005-0.045 mm 0.0002-0.0018 in -
Cotter Thickness 2.99-3.02 mm 0.1177-0.1189 in -
I.D. of 3rd Gear 36.000-36.016 mm 1.4173-1.4179 in When worn or damaged
Sealing Ring Groove Width 2.025-2.060 mm 0.080-0.081 in 2.08 mm 0.082 in
Sealing Ring Thickness 1.89-1.95 mm 0.0744-0.0768 in 1.84 mm 0.0724 in
Reverse Idler Gear (533)

Application Standard or New Service Limit
Metric English Metric English
Axial Clearance 0.07-0.38 mm 0.003-0.015 in -
Gear Shaft O.D. 13.99-14.00 mm 0.5508-0.5512 in When worn or damaged
I.D. of Reverse Idler Gear 18.007-18.020 mm 0.7089-0.7094 in When worn or damaged
I.D. of Transmission Housing at Gear Shaft Contact Area 14.006-14.024 mm 0.5514-0.5521 in -
Thrust Washer Thickness
  • Holder Side
 0.97-1.05 mm 0.038-0.041 in -
  • Transmission Housing
 0.97-1.05 mm 0.038-0.041 in -
Main Control Valve Body Springs (250)

Application Standard or New
Wire Diameter O.D. Free Length No. of Coils
Cooler Check Valve Spring 0.6 mm (0.024 in) 5.8 mm (0.228 in) 14.5 mm (0.571 in) 6.8
CPC Valve C Spring 0.7 mm (0.028 in) 6.1 mm (0.240 in) 17.8 mm (0.701 in) 7.9
Lock-up Shift Valve Spring 0.9 mm (0.035 in) 7.6 mm (0.299 in) 63.0 mm (2.48 in 22.4
Lock-Up Timing Valve Spring 0.65 mm (0.026 in) 6.6 mm (0.260 in) 34.8 mm (1.370 in) 15.6
Lubrication Control Valve Spring 0.7 mm (0.028 in) 7.7 mm (0.303 in) 28.8 mm (1.134 in 10.4
Modulator Valve Spring 1.6 mm (0.063 in) 10.4 mm (0.409 in) 33.5 mm (1.319 in) 9.8
Relief Valve Spring 1.1 mm (0.043 in) 8.6 mm (0.339 in) 32.1 mm (1.264 in) 11.2
Shift Valve A Spring 0.8 mm (0.031 in) 6.6 mm (0.260 in) 49.1 mm (1.933 in) 21.7
Shift Valve B Spring 0.8 mm (0.031 in) 6.6 mm (0.260 in) 49.1 mm (1.933 in) 21.7
Shift Valve D Spring 0.7 mm (0.028 in) 6.6 mm (0.260 in) 32.3 mm (1.268 in) 13.4
Shift Valve E Spring 0.8 mm (0.031 in) 7.1 mm (0.280 in) 49.0 mm (1.929 in) 17.2
Torque Converter Check Valve Spring 1.1 mm (0.043 in) 8.6 mm (0.339 in) 35.0 mm (1.378 in) 12.6
Servo Control Valve Body Springs (325)

Application Standard or New
Wire Diameter O.D. Free Length No. of Coils
CPC Valve A Spring 0.7 mm (0.028 in) 6.1 mm (0.240 in) 17.8 mm (0.701 in) 7.9
Kick-Down Valve Spring 0.8 mm (0.031 in) 6.6 mm (0.26 in) 49.1 mm (1.933 in) 21.7
Reverse CPC Valve Spring 0.7 mm (0.028 in) 6.1 mm (0.240 in) 17.8 mm (0.701 in) 7.9
Servo Control Valve Spring 0.7 mm (0.028 in) 6.6 mm (0.260 in) 35.7 mm (1.406 in) 17.2
Shift Valve C Spring 0.8 mm (0.031 in) 6.6 mm (0.260 in) 49.1 mm (1.933 in) 21.7
Regulator Valve Body Springs (430)

Application Standard or New
Wire Diameter O.D. Free Length No. of Coils
3rd Accumulator Spring 3.1 mm (0.122 in) 19.6 mm (0.772 in) 41.4 mm (1.63 in) 5.5
Lock-Up Control Valve Spring 0.7 mm (0.028 in) 6.6 mm (0.26 in) 42.9 mm (1.689 in) 14.2
0.8 mm (0.031 in) 6.6 mm (0.26 in) 44.3 mm (1.744 in) 25.5
Regulator Valve Spring A 1.9 mm (0.075 in) 14.7 mm (0.579 in) 80.6 mm (3.173 in) 16.1
Regulator Valve Spring B 1.4 mm (0.055 in) 8.8 mm (0.346 in) 44.0 mm (1.7321 in) 12.0
Stator Reaction Spring 5.5 mm (0.217 in) 37.4 mm (1.472 in) 30.3 mm (1.193 in) 2.1
Accumulator Valve Body Springs (495)

Application Standard or New
Wire Diameter O.D. Free Length No. of Coils
1st Accumulator Spring A 2.2 mm (0.087 in) 17.7 mm (0.697 in) 77.6 mm (3.055 in) 12.1
1st Accumulator Spring B 2.0 mm (0.079 in) 11.1 mm (0.437 in) 49.0 mm (1.929 in) 10.0
1st Hold Accumulator Spring 2.0 mm (0.079 in) 13.1 mm (0.516 in) 42.9 mm (1.689 in) 9.8
2nd Accumulator Spring 3.1 mm (0.122 in) 19.6 mm (0.772 in) 53.4 mm (2.102 in) 7.5
4th Accumulator Spring 3.0 mm (0.118 in) 19.6 mm (0.772 in) 45.3 mm (1.783 in) 6.4
5th Accumulator Spring A 2.2 mm (0.087 in) 16.4 mm (0.646 in) 75.7 mm (2.980 in) 14.2
5th Accumulator Spring B 2.0 mm (0.079 in) 10.0 mm (0.394 in) 45.5 mm (1.791 in) 11.6
Front Differential Assembly (919)

Application Standard or New Service Limit
Metric English Metric English
Automatic Transmission 18.000-18.025 mm 0.7087-0.7096 in -
Carrier-to-Output Shaft Clearance 18.000-18.025 mm 0.7087-0.7096 in 0.13 mm 0.005 in
Carrier-to-Intermediate Shaft Clearance 0.045-0.06 mm 0.002-0.004 in -
Tapered Roller Bearing Staring Torque New Bearing 3.9-5.1 N.m (35-45 lb in) 0.080-0.126 mm 0.003-0.005 in - -
Carrier-to-Pinion Shaft Clearance 0.013-0.054 mm 0.0005-0.0021 in 0.1 mm 0.004 in
Driveshaft Contact Area I.D. 30.025-30.055 mm 1.182-1.183 in -
Front Differential Pinion Gear (956)

Application Standard or New Service Limit
Metric English Metric English
Backlash 0.175-0.275 mm 0.007-0.011 in -
I.D. 18.042-18.066 mm 0.7103-0.7113 in -
Pinion Gear-to-Pinion Shaft Clearance 0.055-0.095 mm 0.0022-0.0037 in 0.12 mm 0.005 in
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