Reassembly Chevrolet Avalanche I

Reassembly

Using Piston Installer (J-21363), install intermediate piston to center support. (Scheme 20) Reassemble center support and rear gear unit. (Scheme 21)- (Scheme 24). Install NEW oil seal rings to center support. Soak in manufacturer-recommended transmission fluid prior to installation. See LUBRICATION in appropriate SERVICING article.

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Remove intermediate clutch roller snap ring. Remove intermediate clutch sprag assembly and race, as an assembly. Remove intermediate clutch roller outer race. Inspect intermediate clutch sprag assembly for damaged rollers, damaged cage or distorted springs.
2. Remove direct clutch backing plate snap ring and backing plate. Remove direct clutch plates. Remove direct clutch (waved) plate. Inspect direct clutch backing plate and direct clutch plates for cracks, wear, burned, flaking, scoring and pitting. Install (J-23327 and J-25018-A) spring compressor and adapter, onto direct clutch housing assembly. (Scheme 25) Compress direct clutch spring assembly.
3. Remove direct clutch spring snap ring, and remove spring assembly. Inspect direct clutch spring assembly for collapsed coils and distortion. Remove direct clutch piston assembly. Direct clutch piston assembly is reusable unless it is damaged. Inspect direct clutch piston assembly for damage and cracks. (Scheme 26) Remove direct clutch piston intermediate seal from direct clutch housing assembly.

Scheme 26

Inspect all parts for wear, cracks, burned plates and scoring; replace if necessary.

Scheme 27

1. Install direct clutch piston intermediate seal onto direct clutch housing assembly with seal lip facing upward. Lubricate direct clutch piston assembly with manufacturer-recommended transmission fluid. See LUBRICATION in appropriate SERVICING article. Install (J-21362-1 and J-38732-1) onto direct clutch housing assembly. (Scheme 27) Lubricate tools with manufacturer-recommended transmission fluid. See LUBRICATION in appropriate SERVICING article. Install direct clutch piston assembly into direct clutch housing assembly using rotating motion until direct clutch piston assembly is seated.
2. Install direct clutch spring assembly. Install Spring Compressor and Adapter (J-23327 and J-25018-A) onto direct clutch housing assembly. Compress direct clutch spring assembly, and install direct clutch spring snap ring. Dip all of direct clutch plates in manufacturer-recommended transmission fluid. See LUBRICATION in appropriate SERVICING article. Install direct clutch (waved) plate. Alternate clutch plates, starting with steel clutch plate (5 steel, 5 composite). Install direct clutch plates. Install direct clutch backing plate. Install direct clutch backing plate snap ring.
3. Turn direct clutch housing assembly over. Assemble intermediate clutch sprag assembly into intermediate clutch roller outer race. Install intermediate clutch roller outer race (with grooved side facing up), using a clockwise rotating motion to ease assembly. Clutch roller outer race should not rotate counterclockwise. Install intermediate clutch roller retainer. If intermediate sprag clutch retainer snap ring has been removed, you must use a NEW ring. Install intermediate clutch roller retainer snap ring onto hub of direct clutch housing assembly. Use Snap Ring Installer (J-38695) in order to complete the installation of intermediate clutch roller retainer snap ring. (Scheme 28) Rotate installer counterclockwise while pressing down.
4. To check piston travel, attach (J-7057) extension, (not visible in illustration) to (J-8001-3) dial indicator set. (Scheme 29) Using indicator, mount it to transmission case through opening in case barrel. Place extension onto direct clutch piston assembly. Index dial indicator to Zero. Apply 80 psi of air pressure to direct clutch fluid passage (3rd-Reverse), in case bottom, in order to actuate direct clutch piston. Measure direct clutch piston travel. Piston travel should be.050-.172" (1.3-4.4 mm).

Scheme 28

Scheme 29

Scheme 30

1. Remove direct clutch hub snap ring. (Scheme 31) Remove direct clutch hub. Remove direct clutch housing thrust washer (plastic). Remove forward clutch hub and thrust washer (bronze). Washer may stick to forward clutch housing assembly. Inspect direct clutch hub for spline wear, open lubrication holes or damaged clutch surface.
2. Remove forward clutch snap ring. Remove forward clutch spring assembly. Inspect forward clutch spring assembly for collapsed spring coils and distortion. Remove forward clutch piston assembly (forward clutch piston assembly is reusable if it is not damaged). Inspect forward clutch piston assembly for cracks. Inspect seal on forward clutch piston assembly for cuts, tears and nicks.
3. Remove forward clutch steel and composite plates. Remove forward clutch (waved) plate. Inspect forward clutch plates for burning, scoring, flaking, pitting or wear. Using Spring Compressor and Adapter (J-23327 and J-25018-A), compress forward clutch spring assembly. (Scheme 33) Forward clutch piston intermediate seal assembly is reusable. Replace forward clutch housing assembly if seal is worn or damaged. Inspect forward clutch piston intermediate seal assembly for cuts, tears and nicks. Inspect forward clutch housing assembly for wear, restricted or clogged oil passages, damaged thrust faces and free movement of checkball.

Inspect all clutch plates for cracks, wear, lining separation, pits or other signs of damage. Ensure forward clutch housing check ball is working. Inspect thrust washer for damage. Inspect clutch housing for damaged clutch hub, worn bushings or damaged oil seal rings.

1. Install direct clutch piston intermediate seal onto direct clutch housing assembly with seal lip facing upward. Lubricate direct clutch piston assembly with manufacturer-recommended transmission fluid. See LUBRICATION in appropriate SERVICING article. Install Seal Installers (J-21362-1 and J-38732-1) onto direct clutch housing assembly. (Scheme 27) Lubricate tools with manufacturer-recommended transmission fluid. Install direct clutch piston assembly into direct clutch housing assembly using a rotating motion until direct clutch piston assembly is seated. Install direct clutch spring assembly. Install Spring Compressor and Adapter (J-23327 and J-25018-A) onto direct clutch housing assembly. Compress direct clutch spring assembly. Install direct clutch spring snap ring.
2. Dip all direct clutch plates in manufacturer-recommended transmission fluid. Install direct clutch (waved) plate. Alternate clutch plates, starting with steel clutch plate (5 steel, 5 composite). (Scheme 31) Install direct clutch plates. Install direct clutch backing plate. Install direct clutch backing plate snap ring. Turn direct clutch housing assembly over. When installing intermediate clutch sprag assembly, lip of cage must face direct clutch housing assembly. Assemble intermediate clutch sprag assembly into intermediate clutch roller outer race. Install intermediate clutch roller outer race with grooved side facing up. Use a clockwise rotating motion to ease assembly.
3. Clutch roller outer race should not rotate counterclockwise. Install intermediate clutch roller retainer. If intermediate sprag clutch retainer ring has been removed, a NEW ring must be used. Install intermediate clutch roller retainer snap ring onto hub of direct clutch housing assembly. Use Snap Ring Installer (J-38695) in order to complete installation of intermediate clutch roller retainer retaining ring. (Scheme 28) Rotate installer counterclockwise while pressing down.
4. To check forward clutch piston travel, place turbine shaft in a soft-jawed vice. Install forward clutch housing assembly onto turbine shaft. Install dial indicator. (Scheme 32) With index finger, close one side of fluid passage. Apply compressed air to other side, piston should travel.050-.172" (1.3-4.4 mm).

Scheme 31

Scheme 32

Scheme 33

1. Remove 4th clutch backing plate snap ring. Remove 4th clutch backing plate. Remove clutch plates. Install clutch housing onto Spring Compressor Adapter (J-38731-3). (Scheme 34) Using Spring Compressor (J-38882) and Adapter (J-23327), compress 4th clutch spring assembly. Remove 4th clutch spring snap ring.
2. Remove Spring compressor and adapter. Remove 4th clutch spring assembly. Remove 4th clutch piston. Remove 4th clutch piston inner seal. Remove 4th clutch piston outer seal from 4th clutch housing. Inspect 4th clutch orifice.

Scheme 34

Inspect housing and clutch plates for damaged teeth, scoring or warpage. Ensure 4th clutch housing cup plug bleed hole opening is about .020" (.51 mm).

1. Install 4th clutch piston inner seal onto 4th clutch piston. Install 4th clutch piston outer seal into 4th clutch housing. Seal lip should face bottom of piston when piston is installed. (Scheme 35) Place Seal Installer (J-38731-1) into 4th clutch housing through smaller opening. Place Seal Installer (J-38731-2) onto larger opening of 4th clutch piston. Place Seal Installer (J-38731-2) and 4th clutch piston onto Seal Installer (J-38731-3). (Scheme 35) Install 4th clutch piston into 4th clutch housing by gently pushing down on 4th clutch housing, until 4th clutch piston is through 4th clutch housing, exposing retainer ring groove.
2. Place 4th clutch spring assembly and 4th clutch spring retainer ring onto 4th clutch piston. Using Spring Compressor and Adapters (J-38882), (J-23327) and (J-38731-3), compress 4th clutch spring. (Scheme 34) Install 4th clutch spring retainer ring. Alternate clutch plates, starting with steel clutch plate (4 steel and 4 composite). (Scheme 36) Locate steel plate index notch opposite 4th clutch bolt hole. Install 4th clutch plates into 4th clutch housing. Install 4th clutch backing plate. Align notched tab in same direction as steel plate index notches. Install 4th clutch backing plate retainer ring.
3. Using a feeler gage, measure piston travel between 4th clutch backing plate and 4th clutch backing plate retainer ring. Piston travel should be.040-.100" (1.02-2.54 mm). (Scheme 37)

Scheme 35

Scheme 36

Scheme 37

Remove overrun clutch housing from overdrive carrier assembly. (Scheme 38) Disassemble overrun clutch. (Scheme 39)and (Scheme 47). Using clutch spring compressor and adapter, compress spring retainer and remove clutch piston. (Scheme 40) Disassemble overdrive assembly. (Scheme 47) If necessary, disassemble overdrive carrier assembly. (Scheme 46)

Scheme 38

Scheme 39

Scheme 40

Inspect housing and clutch plates for damaged teeth, scoring or warpage. Inspect spring and spring retainer for damage. Inspect overdrive carrier assembly and turbine shaft for wear or damage. Replace if necessary. Using feeler gauge, ensure overdrive carrier pinion end play is.008-.025" (.20-.64 mm). (Scheme 43)

Scheme 41

1. Remove oil seal rings from turbine shaft. Inspect seal ring grooves for nicks or burrs. Lubricate each oil seal ring. Place Seal Protector/Installer Kit (J-38736) on turbine shaft. (Scheme 41)
2. Quickly slide each seal into ring groove when protector is in position. Use seal driver from Kit (J-38736) to push ring over seal protector. Size seal with seal sizer from Kit (J-38736); gently twist seal sizer over each seal. Leave sizer in place.

1. Using Piston Seal Protector/Installer (J-38729), install piston into overrun clutch housing. (Scheme 42) Lubricate seal with manufacturer-recommended transmission fluid. See LUBRICATION in appropriate SERVICING article. Rotate overrun clutch to aid in assembly. (Scheme 39)
2. Install spring and compress, using compressor. (Scheme 40) Install snap ring. Install steel plate, and then alternate between composition plate and steel plate. Overrun clutch uses 3 steel and 3 composition plates. Install backing plate and snap ring. Using feeler gauge, ensure clearance between backing plate and snap ring is.033-.094" (.84-2.38 mm). (Scheme 44)
3. If necessary, reassemble overdrive carrier. (Scheme 45)- (Scheme 47). Install thrust washer into overdrive carrier. (Scheme 46) To complete reassembly, install turbine shaft and overdrive carrier to overrun clutch. (Scheme 38)and (Scheme 47). When turbine shaft and overdrive carrier are installed into transmission case, install thrust washer onto overrun clutch housing. Place a straightedge from oil pump mating surface to overrun clutch housing thrust washer. (Scheme 48) Both surfaces should be flush.

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Scheme 43

Scheme 44

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Scheme 47

Scheme 48

Clean and air dry oil pump. Disassemble oil pump. (Scheme 49) Note location and direction of all components.

Inspect pump body for porosity, interconnected oil passages, damaged inner pump area surface or damaged machine facing. Check gears and bushings for damage.

1. Reassemble oil pump. Prior to assembly, lubricate all gears with manufacturer-recommended transmission fluid. See LUBRICATION in appropriate SERVICING article. (Scheme 49) Install oil pump gears into pump body with identification dots facing upward. Using straightedge, measure gear clearance between oil pump gears and pump body. Clearance should be.0008-.0028" (.020-.071 mm).
2. Ensure pump body mating surface is flat. Install pump cover onto body. Install cover bolts and hand tighten bolts. Install Alignment Pin (J-25025-1) or pump bolt into pump. Install and tighten oil pump Alignment Band (J-21368). (Scheme 51) Tighten oil pump attaching bolts.
3. To install TCC enable valve, compress spring into oil pump body and insert a small rod into hole "A". (Scheme 50) Install spring retainer and then remove small rod.

Scheme 49

Scheme 50

Scheme 51