Automatic Transmission, 5AT (Introduction): Specifications

Transmission Fluid Temperature (TFT) Sensor Specifications

Temperature	Temperature	Resistance
F°	C°	Ohms
40	40	12370
104	40	964
212	100	155

Transmission Fluid Temperature (TFT) Sensor Specifications

Fastener Tightening Specifications

Component Description	Ref No.	Qty	Bolt Size	Specification
Component Description	Ref No.	Qty	Bolt Size	Metric	English
1st/2nd Clutch Shaft Intermediate Bearing Retainer	133	1 bolt	M6x1.0x20 mm	12 N.m	106 lb in
1st/2nd Clutch Shaft Lube Fluid Pipe Retainer	123	1 bolt	M6x1.0x12 mm	12 N.m	106 lb in
1st/2nd Clutch Shaft Retaining Nut	721	1 nut	26 mm nut	178 N.m	132 lb ft
3rd Clutch Accumulator Piston Bore Cover	418	2 bolts	M6x1.0x30 mm	12 N.m	106 lb in
3rd Clutch Fluid Passage Switch	25		Thread in Sensor	20 N.m	14 lb ft
4th Clutch Fluid Passage Switch	5		Thread in Sensor	20 N.m	14 lb ft
Accumulator Valve Body	483	3 bolts	M6x1.0x85 mm	12 N.m	106 lb in
	482	4 bolts	M6x1.0x95 mm
	476	2 bolts	M6x1.0x110 mm
	479	1 bolt	M6x1.0x125 mm
	478	1 bolt	M6x1.0x140 mm
Automatic Transmission Case Plug	111	7 plugs	8 mm	18 N.m	13 lb ft
Automatic Transmission Case Plug	147	1 plug	10 mm	26 N.m	20 lb ft
Automatic Transmission Fluid Baffle	125	2 bolts	M6x1.0x12 mm	12 N.m	106 lb in
Automatic Transmission Fluid Filter	930	1 bolt	M6x1.0x25 mm	12 N.m	106 lb in
Automatic Transmission Fluid Filter Cover	58	2 bolts	M6x1.0x20 mm	12 N.m	106 lb in
Automatic Transmission Fluid Passage Test Hole Plug	67	5 plugs	8 mm	18 N.m	13 lb ft
Automatic Transmission Fluid Temperature Sensor	21	1 bolt	M6x1.9x18 mm	12 N.m	106 lb in
Automatic Transmission Range Selector Lever	49	1 nut	8 mm	12 N.m	106 lb in
Automatic Transmission Range Selector Lever Cable Bracket	81	1 stud	M6x1.0x28 mm	12 N.m	106 lb in
Automatic Transmission Range Selector Lever Position Switch Shield	64	1 bolt	M6x1.0x16 mm	12 N.m	106 lb in
Clutch Pressure Control Solenoid	17	5 bolts	M6x1.0x25 mm	12 N.m	106 lb in
Clutch Pressure Control Solenoid	16	1 bolt	M6x1.0x55 mm	12 N.m	106 lb in
Control Valve Body	221	2 bolts	M6x1.0x40 mm	12 N.m	106 lb in
	222	2 bolts	M6x1.0x40 mm	12 N.m	106 lb in
	223	3 bolts	M6x1.25x32 mm	18 N.m	13 lb ft
	224	3 bolts	M6x1.0x20 mm	12 N.m	106 lb in
Engine Wiring Harness Bracket	39	1 bolt	M6x1.0x12 mm	12 N.m	106 lb in
Fluid Drain Plug	104	1	18 x 1.5 mm	49 N.m	36 lb ft
Fluid Fill Plug	19	1	24 x 1.5 mm	44 N.m	33 lb ft
Front Differential Carrier, AWD	906	12 bolts left hand thread	M10x1.0x35 mm	101 N.m	75 lb ft
Front Differential Carrier, FWD	096	12 bolts left hand thread	M10x1.0x24 mm	167 N.m	123 lb ft
Front Transmission Mount Bracket Top Nut				90 N.m	64 lb ft
Front Transmission Mount Bracket-to-Transmission Bolts				50 N.m	37 lb ft
Front Transmission Mount-to-Frame Rail Bolts				50 N.m	37 lb ft
Generator Positive Cable Nut				12 N.m	106 lb in
Input Speed Sensor	29	1 bolt	M6x1.0x18 mm	12 N.m	106 lb in
Intermediate Steering Shaft-to-Gear Pinch Bolt				34 N.m	25 lb ft
Lower Transaxle-to-Engine Bolts				64 N.m	47 lb ft
Lube Pipe with Retainer	60	1 bolt	M6x1.0x12 mm	12 N.m	106 lb in
Mainshaft Case Cover Rear	97	3 bolts	M8x1.25x21 mm	19 N.m	14 lb ft
Mainshaft Retainer Nut	110	1 nut	26 mm	178 N.m	132 lb ft
Output Shaft Rear Access Cover	94	2 bolts	M6x1.0x20 mm	12 N.m	106 lb in
Output Shaft Retaining Nut	516	1 left hand thread nut	24 mm	167 N.m	123 lb ft
Output Speed Sensor	32	1 bolt	M6x1.0x18 mm	12 N.m	106 lb in
Park/Neutral Position Switch	44	2 bolts	M6x1.0x16 mm	12 N.m	106 lb in
Park/Neutral Position Switch Locknut	46	1 nut	16 mm	12 N.m	106 lb in
Park Pawl Stop Lever	946	1 bolt	M6x1.0x25 mm	12 N.m	106 lb in
Pressure Regulator Valve Spring Cap Guide	416	1 bolt	M6x1.0x30 mm	12 N.m	106 lb in
Rear Transmission Mount Bracket-to-Engine Bolts				110 N.m	81 lb ft
Rear Transmission Mount-to-Bracket Through Bolt				110 N.m	81 lb ft
Rear Transmission Mount-to-Frame Bolts				50 N.m	37 lb ft
Regulator Valve Body	411	2 bolts	M6x1.0x35 mm	12 N.m	106 lb in
	412	1 bolt	M6x1.0x55 mm	12 N.m	106 lb in
	413	4 bolts	M6x1.0x70 mm	12 N.m	106 lb in
	414	1 bolt	M6x1.0x80 mm	12 N.m	106 lb in
Reverse Idler Gear Retainer Plate	532	2 bolts	M8x1.25x35 mm	26 N.m	20 lb ft
Reverse Idler Rear Access Hole Plug	102	1 plug	20 mm	49 N.m	36 lb ft
Reverse Shift Fork Retainer	926	1 bolt	M6x1.0x20 mm	14 N.m	10 lb ft
Servo Valve Body	312	1 bolt	M6x1.0x60 mm	12 N.m	106 lb in
Shift Cable Bracket Bolts				10 N.m	89 lb in
Shift Control Assembly-to-Bracket Bolts				25 N.m	18 lb ft
Shift Control Solenoid Valves	467	3 bolts	M6x1.0x16 mm	12 N.m	106 lb in
Stabilizer Link Nuts				65 N.m	48 lb ft
Starter Cable Nut				12 N.m	106 lb in
Steering Gear-to-Frame Bolts				110 N.m	81 lb ft
TCC Pressure Control Solenoid Valve	6	1 bolt	M6x1.0x30 mm	12 N.m	106 lb in
TCC Solenoid Valve	467	1 bolt	M6x1.0x16 mm	12 N.m	106 lb in
TOC Lines Bracket Bolt				7 N.m	62 lb in
TOC Line-to-Radiator Fitting				16 N.m	12 lb ft
Torque Converter Housing	107	1 bolt	M10x1.25x80 mm	44 N.m	33 lb ft
	106	12 bolts	M10x1.25x90 mm	44 N.m	33 lb ft
	106	2 bolts	M10x1.25x90 mm	39 N.m	29 lb ft
	90	2 bolts	M10x1.25x100 mm	44 N.m	33 lb ft
	91	5 bolts	M10x1.25x70 mm	44 N.m	33 lb ft
	92	1 bolt	M10x1.25x50 mm	44 N.m	33 lb ft
Torque Converter Inspection Cover Bolts				12 N.m	106 lb in
Torque Converter-to-Flywheel Bolts				12 N.m	106 lb in
Transmission Fluid Baffle	928	1 bolt	M6x1.0x80 mm	12 N.m	106 lb in
Transmission Fluid Baffle	929	1 bolt	M6x1.0x95 mm	12 N.m	106 lb in
Transmission Fluid Cooler Pipe Bracket	51	1 bolt	M6x1.0x14 mm	12 N.m	106 lb in
Transmission Fluid Cooler Pipe Fitting	61	2 fittings		20 N.m	14 lb ft
Transmission Fluid Fill Tube	36	1 bolt	M6x1.0x14 mm	12 N.m	106 lb in
Transmission Lifting Eye	89	2 bolts	M10x1.25x140 mm	44 N.m	33 lb ft
Transmission Lifting Eye Bolt	87	2 bolts	M8x1.25x20 mm	25 N.m	18 lb ft
Transmission Wiring Harness	1	1 bolt	M10x1.0x20 mm	12 N.m	106 lb in
Transmission-to-Engine Mounting Bolts				64 N.m	47 lb ft

Fastener Tightening Specifications

Transmission General Specifications

Name	5AT
RPO Codes	MJ7/MJ8
Vehicle Platform	Z Saturn
Torque Converter Stall Speed	Standard or New: 2,400 RPM Service Limit: 2,250-2,550 RPM
Transmission Fluid Type	ATF-Z1
Position Quadrant	P, R, N, D, I, L

Transmission General Specifications

Fluid Capacity Specifications

Application	Specification
	AWD		FWD
	Metric (Liters)	English (Quarts)	Metric (Liters)	English (Quarts)
ATF at Overhaul	8.1	8.6	8.6	9.1
ATF at Drain / Refill	4.1	4.3	4.5	4.8
Use ATF-Z1

Fluid Capacity Specifications

Fluid Pump Specifications

Application	Standard or New		Service Limit
Application	Metric	English	Metric	English
Driven Gear I.D.	14.016-14.034 mm	0.5518-0.5525 in	When worn or damaged
Driven Gear Shaft O.D.	13.980-13.990 mm	0.5504-0.5508 in	When worn or damaged
Gear-to Body Clearance
Drive Gear	0.210-0.265 mm	0.008-0.010 in
Driven Gear	0.070-0.125 mm	0.003-0.005 in
Gear-to Body Thrust Clearance	0.03-0.06 mm	0.001-0.002 in	0.07 mm	0.003 in

Fluid Pump Specifications

Shim Size Specifications

Mark	Thickness
Mark	Metric	English
1	3.1 mm	0.122 in
2	3.2 mm	0.126 in
3	3.3 mm	0.130 in
4	3.4 mm	0.134 in
5	3.5 mm	0.138 in
6	3.6 mm	0.142 in
7	3.7 mm	0.146 in
8	3.8 mm	0.150 in
9	3.9 mm	0.154 in

1st Clutch Selective Backing Plate (701)

Mark	Thickness
Mark	Metric	English
1	2.1 mm	0.083 in
2	2.2 mm	0.087 in
3	2.3 mm	0.091 in
4	2.4 mm	0.094 in
5	2.5 mm	0.098 in
6	2.6 mm	0.102 in
7	2.7 mm	0.106 in
8	2.8 mm	0.110 in
9	2.9 mm	0.114 in

2nd Clutch Selective Backing Plate (740)

Mark	Thickness
Mark	Metric	English
1	2.1 mm	0.083 in
2	2.2 mm	0.087 in
3	2.3 mm	0.091 in
4	2.4 mm	0.094 in
5	2.5 mm	0.098 in
6	2.6 mm	0.102 in
7	2.7 mm	0.106 in
8	2.8 mm	0.110 in
9	2.9 mm	0.114 in

3rd Clutch Selective Backing Plate (811)

Mark	Thickness
Mark	Metric	English
1	2.1 mm	0.083 in
2	2.2 mm	0.087 in
3	2.3 mm	0.091 in
4	2.4 mm	0.094 in
5	2.5 mm	0.098 in
6	2.6 mm	0.102 in
7	2.7 mm	0.106 in
8	2.8 mm	0.110 in
9	2.9 mm	0.114 in

4th Clutch Selective Backing Plate (609)

Mark	Thickness
Mark	Metric	English
1	2.1 mm	0.083 in
2	2.2 mm	0.087 in
3	2.3 mm	0.091 in
4	2.4 mm	0.094 in
5	2.5 mm	0.098 in
6	2.6 mm	0.102 in
7	2.7 mm	0.106 in
8	2.8 mm	0.110 in
9	2.9 mm	0.114 in

5th/Reverse Clutch Selective Backing Plate (625)

Mark	Thickness
Mark	Metric	English
A	1.525 mm	0.0600 in
B	1.505 mm	0.0593 in
C	1.485 mm	0.0585 in
D	1.465 mm	0.0577 in
E	1.445 mm	0.0569 in
F	1.425 mm	0.0561 in
G	1.405 mm	0.0553 in

Output Shaft, 1st Driven Gear, Selective Spacer, 56 mm (518)

No.	Thickness
No.	Metric	English
A	3.95 mm	0.1555 in
B	3.97 mm	0.1563 in
C	3.99 mm	0.1571 in
D	4.01 mm	0.1579 in
E	4.03 mm	0.1587 in
F	4.05 mm	0.1594 in
G	4.07 mm	0.1602 in
H	4.09 mm	0.1610 in
I	4.11 mm	0.1618 in
J	4.13 mm	0.1626 in
K	4.15 mm	0.1634 in
L	4.17 mm	0.1642 in
M	4.19 mm	0.1650 in
N	4.21 mm	0.1657 in
O	4.23 mm	0.1665 in
P	4.25 mm	0.1673 in
Q	4.27 mm	0.1681 in
R	4.29 mm	0.1689 in
S	4.31 mm	0.1697 in
T	4.33 mm	0.1705 in
U	4.35 mm	0.1713 in

Output Shaft, 3rd/4th Driven Gear, Selective Spacer, 50.2 mm (501)

No.	Thickness
No.	Metric	English
A	2.705 mm	0.107 in
B	2.680 mm	0.106 in
C	2.655 mm	0.105 in
D	2.630 mm	0.104 in
E	2.605 mm	0.103 in
F	2.580 mm	0.102 in
G	2.555 mm	0.101 in
H	2.530 mm	0.100 in
I	2.505 mm	0.099 in
J	2.480 mm	0.098 in
K	2.455 mm	0.097 in
L	2.430 mm	0.096 in
M	2.405 mm	0.095 in

1st/2nd Clutch Shaft, 1st Gear, Selective Washer, 52 mm (722)

No.	Thickness
No.	Metric	English
OA	0.80 mm	0.031 in
A	0.84 mm	0.033 in
B	0.88 mm	0.035 in
C	0.92 mm	0.036 in
D	0.96 mm	0.038 in
E	1.00 mm	0.039 in
F	1.04 mm	0.041 in
G	1.08 mm	0.043 in
H	1.12 mm	0.044 in
I	1.16 mm	0.046 in
J	1.20 mm	0.047 in
K	1.24 mm	0.049 in
L	1.28 mm	0.050 in
M	1.32 mm	0.052 in
N	1.36 mm	0.054 in
O	1.40 mm	0.055 in
P	1.44 mm	0.057 in
Q	1.48 mm	0.058 in
R	1.52 mm	0.060 in
S	1.56 mm	0.061 in
T	1.60 mm	0.063 in
U	1.64 mm	0.065 in
V	1.68 mm	0.066 in
W	1.72 mm	0.068 in
X	1.76 mm	0.069 in
Y	1.80 mm	0.071 in
Z	1.84 mm	0.072 in
AA	1.88 mm	0.074 in
AB	1.92 mm	0.076 in
AC	1.96 mm	0.077 in
AD	2.00 mm	0.079 in
AE	2.04 mm	0.080 in
AF	2.08 mm	0.082 in
AG	2.12 mm	0.083 in
AH	2.16 mm	0.085 in
AI	2.20 mm	0.087 in
AJ	2.24 mm	0.088 in
AK	2.28 mm	0.090 in
AL	2.32 mm	0.091 in

1st/2nd Clutch Shaft, Installed Height, Selective Thrust Shim, 65 mm (74)

No.	Thickness
No.	Metric	English
A	3.995 mm	0.1573 in
B	4.015 mm	0.1581 in
C	4.035 mm	0.1589 in
D	4.055 mm	0.1596 in
E	4.075 mm	0.1604 in
F	4.095 mm	0.1612 in
G	4.115 mm	0.1620 in
H	4.135 mm	0.1628 in
I	4.155 mm	0.1636 in
J	4.175 mm	0.1644 in
K	4.195 mm	0.1652 in
L	4.215 mm	0.1659 in
M	4.235 mm	0.1667 in
N	4.255 mm	0.1675 in

3rd Clutch Shaft, 3rd Gear Clearance, Splined Selective Washer, 53 mm (800)

No.	Thickness
No.	Metric	English
A	1.05 mm	0.041 in
B	1.13 mm	0.044 in
C	1.21 mm	0.048 in
D	1.29 mm	0.051 in
E	1.37 mm	0.054 in
F	1.45 mm	0.057 in
G	1.53 mm	0.060 in
H	1.61 mm	0.063 in
I	1.69 mm	0.067 in
J	1.77 mm	0.070 in
K	1.85 mm	0.073 in
L	1.93 mm	0.076 in
M	2.01 mm	0.079 in
N	2.09 mm	0.082 in

3rd Clutch Shaft, Installed Height, Selective Washer, 26.5 mm (809)

No.	Thickness
No.	Metric	English
A	1.350 mm	0.0531 in
B	1.375 mm	0.0541 in
C	1.400 mm	0.0551 in
D	1.425 mm	0.0561 in
E	1.450 mm	0.0571 in
F	1.475 mm	0.0581 in
G	1.500 mm	0.0591 in
H	1.525 mm	0.0600 in
I	1.550 mm	0.0610 in
J	1.575 mm	0.0620 in
K	1.600 mm	0.0630 in
L	1.625 mm	0.0640 in
M	1.650 mm	0.0650 in
N	1.675 mm	0.0659 in
O	1.700 mm	0.0669 in
P	1.725 mm	0.0679 in
Q	1.750 mm	0.0689 in
R	1.775 mm	0.0699 in
S	1.800 mm	0.0709 in
T	1.825 mm	0.0719 in
U	1.850 mm	0.0728 in
V	1.875 mm	0.0738 in
W	1.900 mm	0.0748 in
X	1.925 mm	0.0758 in
Y	1.950 mm	0.0768 in
Z	1.975 mm	0.0778 in
AA	2.000 mm	0.0787 in
AB	2.025 mm	0.0797 in
AC	2.050 mm	0.0807 in
AD	2.075 mm	0.0817 in
AE	2.100 mm	0.0827 in
AF	2.125 mm	0.0837 in
AG	2.150 mm	0.0846 in
AH	2.175 mm	0.0856 in
AI	2.200 mm	0.0866 in
AJ	2.225 mm	0.0876 in
AK	2.250 mm	0.0886 in
AL	2.275 mm	0.0896 in
AM	2.300 mm	0.0906 in
AN	2.325 mm	0.0915 in
AO	2.350 mm	0.0925 in

Front Differential, Rotational Torque, Selective Shim, 85 mm (910)

No.	Thickness
No.	Metric	English
A	1.82 mm	0.0717 in
B	1.84 mm	0.0724 in
C	1.86 mm	0.0732 in
D	1.88 mm	0.0740 in
E	1.90 mm	0.0748 in
F	1.92 mm	0.0756 in
G	1.94 mm	0.0764 in
H	1.96 mm	0.0772 in
I	1.98 mm	0.0780 in
J	2.00 mm	0.0787 in
K	2.02 mm	0.0795 in
L	2.04 mm	0.0803 in
M	2.06 mm	0.0811 in
N	2.08 mm	0.0819 in
O	2.10 mm	0.0827 in
P	2.12 mm	0.0835 in
Q	2.14 mm	0.0843 in
R	2.16 mm	0.0850 in
S	2.18 mm	0.0858 in
T	2.20 mm	0.0866 in
U	2.22 mm	0.0874 in
V	2.24 mm	0.0882 in
W	2.26 mm	0.0890 in
X	2.28 mm	0.0898 in
Y	2.30 mm	0.0906 in
Z	2.32 mm	0.0913 in
AA	2.34 mm	0.0921 in

Transfer Case Driven Gear with Shaft, Installed Height, Selective Shim, 28.5 mm (912)

Transmission Clearance Specifications

Application	Standard or New		Service Limit
Application	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

Clutch

Application	Standard or New		Service Limit
Application	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

Stator Shaft (404)

Application	Standard or New		Service Limit
Application	Metric	English	Metric	English
Reverse Shift Fork	5.90-6.00 mm	0.220-0.236 in	5.4 mm	0.213 in

Reverse Shift Fork (924)

Application	Standard or New		Service Limit
Application	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

Regulator Valve Body (422)

Application	Standard or New		Service Limit
Application	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

Main Control Valve Body (203)

Application	Standard or New		Service Limit
Application	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

1st/2nd Clutch Shaft, Apply Fluid Collar (129)

Application	Standard or New		Service Limit
Application	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

Mainshaft (640)

Application	Standard or New		Service Limit
Application	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

Output Shaft (535)

Application	Standard or New		Service Limit
Application	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

1st/2nd Clutch Shaft (755)

Application	Standard or New		Service Limit
Application	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

3rd Clutch Shaft (830)

Application	Standard or New		Service Limit
Application	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

Reverse Idler Gear (533)

Application	Standard or New
Application	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

Main Control Valve Body Springs (250)

Application	Standard or New
Application	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

Servo Control Valve Body Springs (325)

Application	Standard or New
Application	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
Lock-Up Control Valve Spring	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

Regulator Valve Body Springs (430)

Application	Standard or New
Application	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

Accumulator Valve Body Springs (495)

Application	Standard or New		Service Limit
Application	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 Assembly (919)

Application	Standard or New		Service Limit
Application	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

Front Differential Pinion Gear (956)

Torque Converter Lock-Up System

The lock-up mechanism of the TCC operates in the D position in 2nd, 3rd, 4th, and 5th gears, in the I position in 2nd and 3rd gears, and in the L position in 2nd gear. The pressurized fluid is drained from the back of the torque converter through a fluid passage, causing the TCC piston (2) to be held against the torque converter cover (1).

As this takes place, the mainshaft (3) rotates at the same speed as the engine crankshaft. Together with the hydraulic control, the PCM optimizes the timing and amount of the lock-up mechanism. When the TCC solenoid valve is turned on by the PCM, the TCC solenoid valve pressure switches the lock-up shift valve lock-up on and off. The AT CPC solenoid valve C and the lock-up control valve control the amount of lock-up.

Automatic Transmission, 5AT (Introduction): Specifications Saturn VUE I

Transmission Fluid Temperature (TFT) Sensor Specifications

Fastener Tightening Specifications

Transmission General Specifications

Fluid Capacity Specifications

Fluid Pump Specifications

Shim Size Specifications

Transmission Clearance Specifications

Torque Converter Lock-Up System

More articles — Automatic Transmission, 5AT (Introduction)

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