Automatic Transaxle Overhaul & Testing - 4T65-E: Overhaul Pontiac Aztek I

ACCUMULATOR ASSEMBLY & 2-1 MANUAL BAND SERVO

1. Remove accumulator cover bolts from 1-2 and 2-3 accumulator cover. (Scheme 47) Remove bolts from 2-1 manual band servo cover. Using screwdriver, gently pry lube oil pipe retainer from case. (Scheme 48) Remove lube oil pipe from front differential carrier internal gear lube hole. (Scheme 49)
2. Remove 1-2 and 2-3 accumulator assembly and 2-1 manual band servo assembly together. Remove pipe assembly. DO NOT twist pipe assembly. Remove cover gasket from 2-1 manual band servo.

Scheme 47

Scheme 48

Scheme 49

Drive & Driven Sprocket Disassembly

1. Remove 4th clutch shaft thrust washer. Remove drive sprocket thrust washer. Washer may be stuck to case cover. Remove VSS reluctor wheel. Note location of drive link assembly master link. Master link is different color than other links and may be facing up or down toward case.
2. Lift drive and driven sprockets with drive link out of case. Lift both sides evenly. It may be necessary to tap turbine shaft up gently with a rubber mallet. Remove drive and driven sprocket thrust washers. (Scheme 51) Thrust washers may be stuck to sprockets.

Scheme 50

Scheme 51

DRIVEN SPROCKET SUPPORT ASSEMBLY

Insert 2 case cover bolts into driven sprocket support assembly. (Scheme 52) Grasp bolts and lift support assembly. Remove thrust washer from 2nd clutch housing. Washer may be stuck to support assembly.

Scheme 52

INPUT & 2ND CLUTCH ASSEMBLIES

1. Adjust collar on Final Drive/Clutch Remover/Installer (J-33381-A) to ensure threaded rod is fully loosened. Install Remover/Installer into 2nd clutch housing assembly. Tighten threaded rod until rod is finger tight. Lift up on remover/installer with 2nd clutch and input clutch assemblies attached. Sprag clutch assemblies will also be attached. (Scheme 53)
2. Place complete assembly on bench. Loosen threaded rod and remove remover/installer. Lift 2nd clutch housing assembly off input clutch housing. Remove input clutch housing thrust bearing from input housing. Remove selective thrust washer from input clutch housing. (Scheme 54)

Scheme 53

Scheme 54

Disassembly & Reassembly

If vent is damaged, use pliers and pry bar to remove vent. (Scheme 55) Use hammer and punch to install vent. If oil pressure test hole plug was removed, install plug and tighten to specification. See TORQUE SPECIFICATIONS.

Scheme 55

Using slide hammer and Universal Seal Remover (J-23129), remove torque converter seal. (Scheme 56) If damage is visible to drive sprocket support bearing, use slide hammer and Bushing/Bearing Remover (J-26941) to remove bearing from drive sprocket support. (Scheme 57) Remove drive sprocket support bolts and remove drive sprocket. (Scheme 58) Install NEW bearing using drive handle and bearing installer. (Scheme 57) Install drive sprocket support. Install and tighten drive sprocket support bolts to specification. See TORQUE SPECIFICATIONS. Using Seal Installer (J-28540) and mallet, install NEW torque converter seal.

Scheme 56

Scheme 57

Scheme 58

Disassembly

1. Using feeler gauge, measure differential carrier planetary pinion gear end play. End play should be.009-.025" (.23-.64 mm). (Scheme 59) If end play is not as specified, repair differential carrier assembly as necessary.
2. Using screwdriver remove retaining ring from front differential carrier. (Scheme 60) Remove planetary pinion gear pin, thrust washers, roller bearings, spacer and pinion gear. (Scheme 61) Remove remaining planetary pinions in same manner. Remove differential carrier sun gear thrust bearing.
3. Place final drive carrier components into oil pan to ensure roller bearings are not lost. Using drift pin and hammer remove differential pinion shaft retaining pin. (Scheme 62) Remove differential pinion gear shaft, gears, pinion gear thrust washers, side gears and side gear thrust washers. (Scheme 63)

Reassembly

1. Assemble differential side gears and thrust washers into carrier. Using petroleum jelly, stick thrust washers onto pinion gears. Assemble pinion gears and thrust washers into differential carrier. (Scheme 63) Rotate gears into position. Slide differential pinion shaft into carrier through pinion gears. Align holes in pinion shaft retaining pin to hole in carrier housing. Using drift pin and hammer, install pinion shaft retaining pin into carrier. (Scheme 62)
2. Apply petroleum jelly to inside of differential carrier planetary pinion gear. For each planetary pinion gear, insert roller bearing spacer onto pin. Spacer must be inserted between 2 rows of roller bearings. Install roller bearings into gear one at a time. Differential ratio of 2.86:1 or 2.84:1 has 2 rows of 18 rollers. All other gear ratios have 2 rows of 22 rollers. (Scheme 65) Occasionally twist pinion gear pin to help align rollers.
3. Install differential carrier sun gear thrust bearing into carrier housing. (Scheme 61) Remove planetary pinion gear pin from its pinion gear. DO NOT move rollers out of position. Attach 2 pinion gear thrust washers on each side of pinion gear. Ensure position of pinion gears in housing is same as when disassembled. Install pinion gear assemblies into carrier housing. Install planetary pinion gear pins. Install retaining ring over planetary pinion gear pins. (Scheme 60)
4. Install final drive sun gear with chamfered side toward parking gear into carrier assembly. Install parking gear onto final drive sun gear shaft. Install final drive sun gear shaft/parking gear assembly into final drive sun gear. Apply petroleum jelly to parking gear side of parking gear thrust bearing and install onto parking gear. (Scheme 64)

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

To remove reluctor wheel, install flat metal stock over output shaft opening. Position Bearing Remover (J-22888) arms onto outer edges of reluctor wheel. Position bearing remover shaft onto flat metal stock. Pull wheel off of carrier. (Scheme 66) To reassemble, heat reluctor wheel slightly. Using plastic mallet, install reluctor wheel onto carrier by tapping evenly around reluctor wheel edge.

Scheme 66

Using small screwdriver, gently pry thrust bearing off of 1-2 support drum. Lift 1-2 support roller clutch assembly out of 1-2 support drum. see scheme 108

Install 1-2 roller clutch assembly into 1-2 support drum. Note position of cage assembly to inner race. see scheme 110 Install thrust bearing onto 1-2 support drum. Press down with hand pressure only.

1. Remove input and 3rd sprag clutch assemblies from input clutch housing. see scheme 115 Remove and discard spiral lock retaining ring from input clutch sprag outer race retainer. Remove 3rd clutch sprag assembly and input clutch sprag assembly from input and 3rd clutch sprag inner race. see scheme 116 Remove input and 3rd clutch sprag inner race and input sun gear spacer from input sun gear.
2. Remove 3rd clutch sprag outer race retainer. Remove input and 3rd clutch sprag end bearings and input and 3rd clutch sprag center bearing from sprag outer races. Remove 3rd clutch and input clutch sprag assemblies from sprag outer races. see scheme 117

1. Position input clutch sprag outer race on flat surface with flat side facing down. Insert end bearing with flat side down into input clutch sprag outer race. Insert input sprag into outer race. see scheme 117
2. Position 3rd clutch sprag outer race on flat surface with beveled side facing down. Install center bearing into 3rd clutch. Install 3rd sprag into 3rd clutch outer race. Lip on sprag cage must be facing up. Insert input and 3rd clutch sprag end bearing into third clutch sprag outer race with flat side up. see scheme 117
3. Install input clutch sprag assembly onto input and 3rd clutch sprag inner race with flat side of input clutch sprag outer race facing down. Install 3rd clutch sprag assembly onto input and 3rd clutch sprag inner race with beveled side of 3rd clutch sprag outer race facing input clutch sprag assembly. Install 3rd clutch sprag outer race retainer onto 3rd clutch sprag outer race. see scheme 117
4. Using small flat-blade screwdriver, install retaining ring onto input clutch sprag. Assemble spacer onto input sun gear. Install input and 3rd sprag clutch assemblies onto input sun gear. see scheme 118

1. Using flat-blade screwdriver, remove retaining ring from input clutch housing. Remove input clutch backing plate. Remove all input clutch plate assemblies. Remove input clutch waved plate and input clutch apply plate. see scheme 120
2. Using flat-blade screwdriver, remove retaining ring from input clutch housing. Remove 3rd clutch backing plate. Remove 3rd clutch plate assembly. Remove 3rd clutch waved plate. see scheme 121 Remove input shaft thrust bearing. see scheme 122
3. Using spring compressor and adapter, compress 3rd clutch spring assembly. Using snap ring pliers, remove retaining ring from input clutch housing. see scheme 123 DO NOT over expand retaining ring during removal. Remove adapter, spring compressor and 3rd clutch spring assembly. Remove 3rd clutch piston and seal. see scheme 124
4. Using spring compressor, compress input clutch spring and retainer assembly. Using snap ring pliers, remove retaining ring from input clutch housing. see scheme 125 DO NOT over expand retaining ring during removal. Remove spring compressor. Remove 3rd clutch piston housing, spring assembly and input clutch piston. see scheme 126
5. Remove 3rd clutch piston inner seal, 3rd clutch housing "O" ring seal and input clutch piston inner seal. Cut and remove input shaft oil seal rings. DO NOT damage grooves on shaft when oil seal ring is removed. see scheme 127

1. Lubricate NEW input clutch piston inner seal with ATF. Using Input Clutch Inner Piston Seal Protector (J-37361), install input clutch piston inner seal onto input clutch housing. see scheme 129 Install NEW "O" ring seal in input clutch housing. see scheme 130 Lubricate NEW 3rd clutch piston inner seal with ATF. Using Third Clutch Inner Piston Seal Protector (J-37362), install 3rd clutch piston inner seal onto input clutch housing. see scheme 131
2. Lubricate NEW input clutch piston outer seal with ATF, install seal onto piston. see scheme 132 Install input clutch piston into input clutch housing. Install input clutch spring and retainer into input clutch housing. Install 3rd clutch piston housing into input clutch housing. see scheme 126 Using spring compressor and snap ring pliers, install retaining ring in 3rd clutch housing. see scheme 125 Remove spring compressor.
3. Lubricate NEW 3rd clutch piston assembly with ATF and install into input housing. Install 3rd clutch spring assembly into input housing. see scheme 124 Using spring compressor, adapter and snap ring pliers, install 3rd clutch housing retaining ring. see scheme 123
4. Insert 3rd clutch waved plate into input housing. Install first external splined plate with steel side against waved plate. Place composition side of all plates facing up. Install 3rd clutch plates into input housing. Start by inserting a steel 3rd clutch plate with external splines. Alternate with internal splined plates. Install 3rd clutch backing plate with UP marking facing up. Install retaining ring into input housing. see scheme 121
5. Install input clutch apply plate into input housing with notched side of teeth facing downward against retaining ring on 3rd clutch backing plate. Install input clutch waved plate. Install input clutch plates starting with an input clutch steel plate and alternating with input clutch composition plate. Install input clutch backing plate with tapered teeth side facing up. Install retaining ring on input clutch housing. see scheme 120 Install input shaft thrust bearing into input clutch housing. see scheme 122

Using 1/4" drift and hammer, remove check ball valve from input clutch housing. To reassemble, use 3/8" drift and hammer to install check ball valve into input clutch housing. (Scheme 67)

Scheme 67

Using small screwdriver, align teeth of input clutch plate assembly with 3rd clutch plate assembly. Ensure sprag assembly is fully seated into housing. Insert combined input sprag clutch and 3rd sprag clutch assembly into input clutch housing assembly. see scheme 115

Using flat-blade screwdriver, remove retaining ring from 2nd clutch housing. Remove backing plate, composition plates, steel plates, apply plate and waved plate. (Scheme 68) Using spring compressor, compress 2nd clutch piston spring. Remove retaining ring. (Scheme 69) Remove 2nd clutch spring assembly and 2nd clutch piston. (Scheme 70)

1. Install Adapter (J-41992-3) into NEW 2nd clutch piston. Install piston and adapter into Protector (J-41992-1). Install piston assembly into 2nd clutch housing. Center inner seal protector onto hub by pressing down on center of protector. Install Piston Installer (J-41992-2) onto protector. Legs of installer go into slots of protector. Use hand pressure to press down on installer until piston is seated. (Scheme 72)
2. Install 2nd clutch spring assembly into housing. Install retaining ring. (Scheme 69) Install waved plate. Install apply plate into 2nd clutch housing with DN or DOWN marking toward piston. Install composition plates and steel plates, starting with composition plate and alternating each plate. Install backing plate and retaining ring. (Scheme 68)

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Note. If check ball valve does not leak, DO NOT replace.

Remove check ball valve from housing using 1/4" drift and hammer. (Scheme 73) Tap in NEW check ball assembly using same drift and hammer. (Scheme 74)

Scheme 73

Scheme 74

Using appropriate spring compressor, compress 4th clutch spring assembly. Remove snap ring from driven sprocket support assembly. see scheme 143 Remove spring compressor, spring assembly and 4th clutch piston from driven sprocket support assembly. Remove inner seal from driven sprocket support assembly hub. Remove oil seal rings and 4-lobed ring seals from driven sprocket support assembly. see scheme 144 Remove outer seal from piston. see scheme 145

1. Lubricate NEW inner and outer seal with ATF prior to installation. Install outer seal on 4th clutch piston. see scheme 145 Install inner 4th clutch piston seal onto driven sprocket support hub. see scheme 146
2. Install 4th clutch piston into driven sprocket support and align components. Install 4th clutch spring assembly into piston. see scheme 144 Using spring compressor, compress spring assembly and install snap ring. see scheme 143 Lubricate NEW oil seal rings for 2nd clutch housing. Install oil seal rings and 4-lobed ring seals onto driven sprocket support hub. see scheme 144

Using Driver Handle (J-8092), Bearing Remover (J-34129) and hammer, drive driven sprocket support bearing from support. (Scheme 75) To reassemble, position driven sprocket support bearing assembly so markings on edge of bearing are facing up. Using Driver Handle (J-8092), Bearing Installer (J-34126) and hammer, seat bearing flush to or below support hub. (Scheme 76)

Scheme 75

Scheme 76

1. Install selective thrust washer and thrust bearing assembly onto input clutch housing assembly. (Scheme 54) Using small screwdriver, align 2nd clutch teeth. Install 2nd clutch housing assembly onto 2nd clutch hub of input clutch housing assembly.
2. Install Final Drive/Clutch Remover/Installer (J-33381-A) into 2nd clutch housing and input clutch housing. Sprag clutch assemblies will also be attached. (Scheme 53) Tighten threaded rod until rod is finger tight.

Cut oil seal rings from turbine shaft. Remove oil seal rings. Remove drive sprocket retaining ring. Remove drive sprocket from turbine shaft. (Scheme 77)

1. Insert turbine shaft into drive sprocket and install retaining ring. (Scheme 77)
2. Install Turbine Shaft Seal Installer/Expander (J-29569-1) onto chain side of turbine shaft. Coat turbine shaft seal installer/expander with petroleum jelly. Slide turbine shaft oil seal rings into position. (Scheme 80)
3. Using Turbine Shaft Seal Installer/Compressor (J-29569-2), size chain side turbine shaft oil seal rings. (Scheme 81)
4. Install Turbine Shaft Seal Installer/Expander (J-29829-1A) onto converter side of turbine shaft. Coat turbine shaft seal installer/expander with petroleum jelly. Slide turbine shaft oil seal ring into position. (Scheme 82)
5. Using Turbine Shaft Seal Installer/Compressor (J-29829-2), size converter side turbine shaft oil seal ring. (Scheme 83)

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Note. For drive and driven sprocket component reassembly, see TRANSAXLE REASSEMBLY .

Scheme 84

Remove manual valve. Remove 3-4 accumulator piston cylinder and 3-4 accumulator piston "O" ring seal. Use low pressure compressed air from valve body side if necessary for removal. Remove 3-4 accumulator piston outer and inner spring, piston and pin from valve body side of case cover. Remove actuator feed limit valve spring retainer, spring and valve. (Scheme 85)

Install NEW 3-4 accumulator piston cylinder "O" ring seal onto 3-4 accumulator piston cylinder. Install 3-4 accumulator piston outer and inner spring into 3-4 accumulator piston cylinder. Install NEW 3-4 accumulator piston seal onto 3-4 accumulator piston. Insert 3-4 accumulator piston into 3-4 accumulator piston cylinder. Using a slight twisting motion, insert 3-4 accumulator piston cylinder into case cover. Insert 3-4 accumulator piston pin through front of case cover and into 3-4 accumulator piston. Install manual valve into case cover. Install actuator feed limit valve, spring and spring retainer into case cover. (Scheme 85)

Scheme 85

Scheme 86

Scheme 87

Note. When drive axle is removed from transaxle for any reason, inspect axle sealing surface (tripot shank) for corrosion. If corrosion is evident, clean surface with 320-grit cloth or equivalent. Clean off any remaining debris with ATF. Wipe surface dry and reinstall drive axle free of any build up.

Install NEW left axle shaft oil seal onto Left Side Axle Seal Installer (J-34115). Using left side axle seal installer and mallet, install left side axle oil seal assembly. (Scheme 88)

Scheme 88

Thoroughly clean and air dry control valve body. Remove each valve train, noting location of each component. Some valves are under spring pressure, cover bores when removing retainers. Remove retainers with small screwdriver. Position valves, springs and bushings on clean surface in order removed. (Scheme 89)& (Scheme 90).

To reassemble valve body components, reverse disassembly procedure. Ensure all components are installed in original locations. (Scheme 89)& (Scheme 90).

Scheme 89

Scheme 90

OIL PUMP ASSEMBLY

Remove oil pump cover bolt and oil pump cover. Remove pump rotor, vane rings, vanes, oil seal ring and slide "O" ring seal. Remove outer and inner oil pump prime springs, slide seal and slide seal support. Remove slide pivot pin. Remove outlet screen. see scheme 166

Remove servo piston cylinder from servo cover. Remove "O" ring seal from servo piston cylinder. Remove piston assembly, servo piston spring and servo exhaust screen from cylinder. Remove servo piston seal from piston. Using small screwdriver, remove retaining ring from servo piston pin. Remove servo piston, cushion spring and spring retainer from servo piston pin. (Scheme 91)

Install servo piston spring retainer, cushion spring and servo piston onto servo piston pin. Install servo piston pin retaining ring. Install servo piston seal onto piston. Lubricate seal with ATF. Install servo exhaust screen and servo piston cylinder "O" ring seal onto cylinder. Lubricate "O" ring seal with ATF. Attach servo piston spring to piston assembly. Install servo piston assembly into cylinder assembly and set assemblies aside.

Scheme 91

1. Remove 7 remaining accumulator cover bolts from accumulator assembly. Remove accumulator cover and spacer plate from accumulator housing. Disassemble 1-2 and 2-3 accumulator pistons, piston pins, outer springs and cushion springs from accumulator housing (springs are model dependent). Remove piston oil seal rings from 1-2 and 2-3 accumulator pistons. (Scheme 92)
2. Disassemble 2-1 manual band servo and forward band servo oil pipes, lube oil pipe assembly from accumulator cover, and 2-1 manual band servo cover. Disassemble lube oil pipe, hose clamps, oil hose, lube oil pipe retainer and lube oil pipe with washer. (Scheme 93)

1. Install piston oil seal rings onto 1-2 and 2-3 accumulator pistons. Lubricate oil seal ring with ATF. Assemble 1-2 and 2-3 piston pins and pistons. Assemble 1-2 and 2-3 accumulator piston springs and piston assembly into accumulator housing. (Scheme 92)
2. Assemble accumulator spacer plate and cover onto accumulator housing. Install accumulator bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000).
3. Assemble lube oil pipe, oil hose, hose clamps, pipe retainer and pipe with washer. (Scheme 93) Install 2-1 manual band servo and forward band servo oil pipes into accumulator assembly. Install 2-1 manual band servo and forward band servo oil pipes into 2-1 manual band servo cover. Install lube oil pipe assembly into accumulator assembly.

Scheme 92

Scheme 93

Dissemble servo piston spring from servo assembly. Remove servo piston oil seal ring from servo piston. Remove servo pin retaining ring from servo piston pin. Disassemble servo piston, servo piston cushion spring, retainer and servo piston pin. see scheme 16

Assemble servo piston, servo piston cushion springs, retainer and servo piston pin. Install servo pin retaining ring onto servo piston pin. Install servo piston oil seal ring onto servo piston. Install servo piston spring onto servo assembly. (Scheme 94)

Scheme 94

Remove return spring from reverse band servo assembly. Remove oil seal ring from servo piston. Using a small screwdriver, remove retaining ring from servo piston apply pin. Disassemble servo piston, servo piston cushion springs, servo piston cushion spring retainer and servo piston apply pin. (Scheme 95)

Assemble servo piston, cushion springs, cushion spring retainer and servo piston apply pin. Install retaining ring onto servo piston apply pin. Install oil seal ring onto servo piston. Install return spring onto servo assembly. (Scheme 95)

Scheme 95

TRANSAXLE REASSEMBLY

Note. End play checks performed during TRANSAXLE DISASSEMBLY procedure must be rechecked at appropriate reassembly stage. For thrust washer, thrust bearing, bushing and seal installation direction and location during reassembly, refer to appropriate illustration. see scheme 188- see scheme 192.

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

1. Install shift and park linkage components into case. See «PARKING SYSTEM COMPONENTS»(ref-131089-S16102544092001121000000) under COMPONENT DISASSEMBLY & REASSEMBLY. Install final drive internal gear assembly into case. Align parking pawl with parking pawl actuator. Using long screwdriver, install retaining ring into case. see scheme 86
2. Position transaxle with oil pan flange facing down. Ensure sun gear thrust bearing is installed into differential carrier. Install differential carrier sun gear. Step in sun gear must be pointing toward parking gear. Install parking gear. Install internal gear thrust bearing into differential carrier. Ensure bearing is positioned properly. Install sun gear shaft into differential carrier. (Scheme 64) Install differential carrier into case. (Scheme 96)
3. Install selective thrust washer and thrust bearing onto differential carrier. Install seal onto case extension. Install case extension onto transaxle case. see scheme 56 Install and tighten 2 case extension bolts only until case extension is seated into case. DO NOT torque bolts.
4. Position transaxle case with flange for case cover facing up. Install forward band into case. Locate band onto forward band anchor pin and apply pin feature in case opening. Install thrust washer onto final drive internal gear. see scheme 85
5. Install 1-2 support drum. see scheme 84 Position 2-1 band on anchor pin. see scheme 83 Install reaction sun gear and drum. see scheme 82 Ensure sun gear and drum fully engage 1-2 support roller clutch. Check roller clutch for correct operation. see scheme 111
6. Install reaction carrier/sun gear thrust bearing onto reaction carrier. Install reaction carrier into transaxle case and rotate carrier so pinions engage reaction sun gear. Install thrust bearing and lube dam onto input carrier. Install input carrier into transaxle case and rotate carrier so pinions engage reaction carrier internal gear. see scheme 114
7. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch hubs must engage clutch plates. 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.
8. Check input clutch housing end play. See «INPUT CLUTCH HOUSING END PLAY CHECK»(ref-131089-S03730630512001121300000) under TRANSAXLE DISASSEMBLY. Using feeler gauge, check clearance between thrust washer and end play gauge. Clearance must be.0-.006" (.0-.15 mm). If clearance is not as specified, use different thrust washer. See «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(ref-131089-S05760487062001121000000) table. Remove input clutch assembly. INPUT CLUTCH THRUST WASHER IDENTIFICATION Washer ID No. Color Thickness - In. (mm) 1 Orange/Green.114-.118 (2.90-3.00) 2 Orange/Black.120-.124 (3.05-3.15) 3 No Color.126-.130 (3.20-3.30) 4 White.132-.136 (3.35-3.45) 5 Blue.138-.142 (3.50-3.60) 6 Pink.144-.148 (3.65-3.75) 7 Brown.150-.154 (3.80-3.90) 8 Green.156-.159 (3.95-4.05) 9 Black.161-.165 (4.10-4.20) 10 Purple.167-.171 (4.25-4.35) 11 Purple/White.173-.177 (4.40-4.50)
9. Check for damaged 2nd clutch and reverse reaction drum splines. Original 2nd clutch and reverse reaction drums have splines with 25-degree sides and have tendency to strip. New design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) has splines with 10-degree sides. Install reverse reaction drum. see scheme 75
10. Install reverse band into case, locating band on anchor pins. see scheme 74 Install selective thrust washer and thrust bearing onto input clutch assembly. Install thrust bearing with large race facing down. Install 2nd clutch assembly onto input clutch assembly. Clutch plates must engage input clutch hub. (Scheme 54)
11. Install final drive/clutch installer into assembled input and second clutch housing assemblies. Tighten threaded rod of final drive/clutch installer until rod is finger tight. Using final drive/clutch installer, lift input and second clutch housing assembly, and install input and second clutch housing assembly into case. (Scheme 53) Ensure input clutch housing assembly is fully seated. Ensure second clutch housing is.500" (13 mm) above top of reverse band assembly.
12. Install thrust washer onto driven sprocket support, and hold washer in position with petroleum jelly. Install driven sprocket support into case. (Scheme 52) Ensure support is flush with or below case.
13. Use petroleum jelly to hold thrust washer onto drive and driven sprockets. (Scheme 51). Assemble drive and driven sprockets into drive chain assembly as follows: If old drive link is being reinstalled, assemble drive link and sprockets with master link (different color link) facing in same direction as removed. See «DRIVE & DRIVEN SPROCKETS»(ref-131089-S24279932422001121000000) under TRANSAXLE DISASSEMBLY. If NEW drive link assembly is being installed, assemble drive link and sprockets with master link facing upward.
14. Install drive link assembly and sprockets into case. A slight rocking motion may be required to work sprockets into place. Install input speed sensor reluctor wheel onto drive sprocket. (Scheme 51) Perform DRIVE CHAIN (DRIVE LINK) STRETCH CHECK. See «DRIVE & DRIVEN SPROCKETS»(ref-131089-S24279932422001121000000) under TRANSAXLE DISASSEMBLY.
15. Install 4th clutch shaft thrust washer onto driven sprocket. Insert 4th clutch shaft into transaxle case through driven sprocket. see scheme 68 Shaft must fully seat into input sun gear. Install drive link lube scoop into case.
16. Install fourth clutch apply plate over fourth clutch shaft assembly and into driven sprocket support with machined side towards driven sprocket. Install remaining 4th clutch plates, starting with composition plate and alternating with steel plates. Clutch plates should align in driven sprocket support. see scheme 68
17. Install pistons and pins into case cover. Install springs into case cover. (Scheme 85) Install case cover gaskets. see scheme 67 Install 4th clutch shaft and drive sprocket thrust washers onto case cover. see scheme 66
18. Install case cover onto transaxle case. Case cover lugs must align with tangs on 4th clutch plates. see scheme 17 Install case cover bolts. See «CASE COVER BOLT SPECIFICATIONS»(ref-131089-S06119074732001121000000) table. Tighten case cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000). CASE COVER BOLT SPECIFICATIONS Bolt No. (1) Diameter - In. (mm) Length - In. (mm) 1 0.24 (6) 1.3 (32) 2 0.24 (6) 1.6 (40) 3 0.31 (8) 2.0 (50) 4 0.24 (6) 1.2 (30) (1) For bolt location, refer to illustration. see scheme 65
19. Install oil dam into case. see scheme 63 Connect manual valve link to manual valve. see scheme 62 Install manual shift detent and bolt. see scheme 61 Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000).
20. Install input speed sensor and clip into case cover. see scheme 64
21. On 2 wheel drive models, check front differential carrier end play. See «FRONT DIFFERENTIAL CARRIER END PLAY CHECK»(ref-131089-S27258865972001121000000) under TRANSAXLE DISASSEMBLY. Install appropriate thrust washer on to input shaft and hold in position with petroleum jelly. See «CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES»(ref-131089-S35041388482001121000000) table. Tighten case extension bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000).
22. Install oil pump drive shaft. see scheme 55 Install 2 large check balls and 4 small check balls into control valve body. see scheme 54 Install 4 check balls into case cover. see scheme 53 Use petroleum jelly to hold check balls in position.
23. Install solenoid screen/seal assemblies into spacer plate. Install case cover guide pin into case cover. Install valve body-to-spacer plate gasket, spacer plate and case cover-to-spacer plate gasket onto control valve body. Install bolts to hold spacer plate and gaskets onto control valve body. (Scheme 97)
24. Install control valve body onto case cover. Use case cover pin and turbine sleeve in case cover as guides. Ensure check balls do not drop out of control valve body during reassembly. (Scheme 98) Install manual valve position switch onto control valve body. see scheme 51
25. Install control valve body bolts. See «VALVE BODY BOLT SPECIFICATIONS»(ref-131089-S19953295192001121000000) table. Finger tighten bolts to prevent cross-threading. Tighten bolts in a spiral pattern starting with bolts at center of control valve body. If bolts are tightened at random, valve bores may become distorted and prevent proper valve operation. Tighten valve body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000).
26. Install oil pump assembly onto control valve body. see scheme 49 Install oil pump bolts in specified locations. See «OIL PUMP BOLT SPECIFICATIONS»(ref-131089-S19815416392001121000000) table. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000). Install electronic components and wiring harness. Ensure wire connectors are installed in correct locations. see scheme 46 VALVE BODY BOLT SPECIFICATIONS Bolt No. (1) Diameter - In. (mm) Length - In. (mm) 1 0.24 (6) 2.6 (65) 2 0.24 (6) 2.4 (60) 3 0.24 (6) 1.2 (30) 4 0.24 (6) 1.8 (45) 5 0.24 (6) 2.2 (55) 6 0.24 (6) 3.7 (95) 7 0.31 (8) 3.5 (90) 8 0.24 (6) 0.8 (20) 9 0.24 (6) 3.3 (85) (1) For bolt location, refer to illustration. see scheme 50 OIL PUMP BOLT SPECIFICATIONS Bolt No. (1) Diameter - In. (mm) Length - In. (mm) 1 0.24 (6) 0.8 (20) 2 0.24 (6) 3.7 (95) 3 0.24 (6) 3.3 (85) (1) For bolt location, refer to illustration. see scheme 48
27. Install side cover gasket and seal onto transaxle case. see scheme 15 Install case side cover. see scheme 45 Tighten side cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000).
28. Install 2-1 manual band servo and cover gasket into case. Lubricate gasket with ATF. (Scheme 99) Ensure servo piston pin engages band. Install accumulator and 2-1 manual band servo cover assembly into case. (Scheme 100) Install lube oil pipe into case at lube hole for differential carrier internal gear. Lock lube oil pipe retainer into case. (Scheme 48) Install cover bolts for 2-1 manual band servo. Install accumulator cover and bolts. (Scheme 47) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000).
29. Using socket and mallet, install NEW oil filter seal. (Scheme 101) Install oil filter and pan gasket into case. Install oil pan and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000).
30. Position transaxle so oil pan is facing up. Install servo cover seal onto forward band servo cover. Install forward band servo assembly into servo cover. Pivot servo assembly into servo cover to prevent piston oil seal ring from being damaged. Install servo and cover assembly into case. see scheme 41
31. Using long screwdriver, pry against work bench to compress forward band servo assembly. see scheme 40 Hold servo assembly compressed. Install 3 forward band servo cover bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000).
32. Position transaxle so oil pan is facing down. Install "O" ring seal onto reverse servo cover. Install servo and cover assembly into case. see scheme 39 Use a long screwdriver to depress reverse band servo cover by prying against transaxle holding fixture. see scheme 38 Hold reverse band servo assembly compressed. Using a small screwdriver, install reverse band servo cover retaining ring.
33. Install VSS. Install "O" ring onto turbine shaft. Install torque converter.
34. On 2WD models, affix outboard and inboard drive shaft retaining rings onto output shaft. DO NOT push to hard during installation of output shaft, or damage to bushings or bearings may occur. Carefully install output shaft into transaxle. Extend shaft through differential side gear. On AWD models, DO NOT install output shaft until after performing «TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK»(ref-131089-S12404971462001122100000) and reinstalling transfer case.

CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES