TRANSAXLE REASSEMBLY Pontiac Aztek I

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