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Transaxle Reassembly

NOTE: Note location of all gear sets, clutch plates, thrust bearings, thrust washers and bushings. See Figure and Figure. Recheck snap ring and thrust washer measurements taken during disassembly. See appropriate procedures under COMPONENT DISASSEMBLY & REASSEMBLY .
  1. Lubricate all bushings, seals, thrust bearings and internal mating surfaces with ATF 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 1.
    Fig 1: 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 Figure. 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 11/16". See Fig 2.
    Fig 2: 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 element (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 3. 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. 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.
  19. Install control valve body and bolts. See Fig 4. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install valve body wiring harness. Ensure wiring harness is routed properly. See Figure. Connect lever link to T.V. bracket. Install T.V. bracket onto valve body.
  20. 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 5.
    Fig 3: Locating Case Cover Bolts
    G92E12702Courtesy of GENERAL MOTORS CORP.
    Fig 4: Locating Control Valve Body Bolts
    G92F12703Courtesy of GENERAL MOTORS CORP.
    Fig 5: Applying Sealant To Case Cover & Oil Pan Bolts
    G92G12704Courtesy of GENERAL MOTORS CORP.
  21. 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.
  22. 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.
  23. 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.
  24. 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 5. Rotate transaxle so oil pan side is down.
  25. 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. Ensure governor shaft is piloted in governor cover before tightening cover bolts. Install torque converter.
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