Part 2

Transmission Overhaul Procedure Continued





82. Using a screwdriver, remove the snap ring from the transaxle case.





83. Remove the flange, plates and 1st and reverse brake clutch discs from the transaxle case.





84. Check the 1st and reverse clutch discs. If the sliding surfaces of the discs, plates and flanges are worn, discolored, or if a part of the printed numbers are defaced, replace all the discs and plates.





85. Using a press, slightly compress the return spring until the snap ring is free from the return spring.





86. Using snap ring pliers, remove the snap ring.





87. Using compressed air at low pressure 98 kPa (14 psi) push out the 1st and reverse brake piston from the transaxle case.





88. Using a screwdriver, remove the 2 O-rings from the 1st and reverse brake piston.





89. Remove the 13 bolts from the transaxle case.





90. Using a soft faced hammer, tap the rear transaxle case cover to remove the rear case from the transaxle case.





91. Using a punch and hammer, unstake the counterdrive gear nut.





92. Remove the counterdrive gear nut.





93. Remove the intermediate shaft sub-assembly from the transaxle case.





94. Using a press, remove the counterdrive gear (1) from the transaxle case.
95. Remove the snap ring from the counterdrive gear bearing.
96. Remove the counterdrive gear bearing from the counterdrive gear.





97. Using a punch and hammer, unstake the counterdriven gear nut.





98. While holding the counter shaft assembly (1), remove the counterdriven gear nut.
99. Using a suitable puller, remove the counterdriven gear.





100. Remove the thrust bearing from the transaxle case.





101. Pull out the counter shaft from the transaxle case.





102. Remove the needle bearing from the counter shaft assembly.





103. Install a dial indicator (1) on the underdrive clutch piston.





104. Important: If the piston stroke is not within 1.5 - 1.9 mm (0.059 - 0.075 inch). Install a new flange during assembly.

While applying and releasing compressed air at a pressure of 392 - 785 kPa (57 - 114 psi) measure the piston stroke.





105. Remove the underdrive clutch assembly from the transaxle case.
106. Remove the underdrive 1 way clutch retainer from the transaxle case.





107. Hold the 1 way clutch drum (1) and turn the 1 way clutch (2). The 1 way clutch should turn freely counterclockwise (3) and should lock if turned clockwise (4).





108. Remove the 1 way clutch assembly and the underdrive clutch drum thrust washer (1) from the underdrive clutch drum.





109. Remove the 2 overdrive clutch drum oil seal rings from the transaxle case.





110. Install a dial indicator on the underdrive brake pack.

111. Important: If the clearance is not within 1.15 - 1.97 mm (0.0453 - 0.0766 inch). Inspect the discs.

While applying compressed air, measure the pack clearance.





112. Using a press, compress the flange until the snap ring is accessible.
113. Using a screwdriver, remove the underdrive clutch flange snap ring from the transaxle case.





114. Remove the flange, plates and underdrive clutch discs.





115. Check the sliding surfaces of the plates and clutch discs. If the sliding surfaces of the discs, plates and flanges are worn, discolored, or if a part of the printed numbers are defaced, replace all the discs and plates.





116. Remove the underdrive brake return spring sub-assembly from the transaxle case.





117. Using compressed air at low pressure 98 kPa (14 psi) push out the underdrive brake piston from the transaxle case into a shop towel.





118. Using a screwdriver, remove the 2 O-rings from the underdrive brake piston.





119. Remove the 2 bolts, pawl stopper plate, torsion spring and spring guide sleeve from the transaxle case.





120. Remove the bolt and pawl shaft clamp from the transaxle case.





121. Remove the parking lock pawl shaft and parking lock pawl from the transaxle case.





122. Remove the spring guide sleeve from the transaxle case.





123. Remove the cam guide sleeve from the transaxle case.





124. Using a TORX� bit, remove the 7 screws.





125. Remove the 2 bolts.
126. Remove the transmission case plate No. 2 and the case plate gasket from the transaxle case.





127. Remove the B-4 accumulator piston and spring from the transaxle case.
128. Remove the 2 O-rings from the piston.
129. Remove the bolt and the transmission case plate No.3 from the transaxle case.





130. Using a suitable puller, remove the counterdriven gear roller bearing from the transaxle case.





131. Remove the bolts and transaxle apply tube clamps from the transaxle case.





132. Using a screwdriver, remove the lube apply tube from the transaxle case.
133. Using a screwdriver, remove the differential gear apply tube from the transaxle case.





134. Remove the bolt and the underdrive roller bearing retainer from the transaxle case.





135. Using a puller, remove the roller bearing from the transaxle housing.





136. Using a screwdriver, remove the housing oil seal from the transaxle case.





137. Using a screwdriver, remove the transaxle case oil seal from the transaxle case.
138. Using a bearing puller, remove the front drive pinion roller bearing from the differential case.
139. Using a bearing puller, remove the rear drive pinion roller bearing from the differential case.





140. Using a press, drive out the front pinion front roller bearing outer race.





141. Drive out the front drive pinion rear roller bearing outer race and adjusting shim from the transaxle case.





142. Using a press, install a new front drive pinion rear roller bearing on the differential case.





143. Place the adjusting shim in the transaxle case.
144. Using a press, install a new front drive pinion rear roller bearing outer race in the transaxle case.





145. Install the speedometer drive gear on the differential case.





146. Using a press, install a new front drive pinion front roller bearing in the transaxle case.





147. Using a press, install a new front drive pinion front roller bearing outer race in the transaxle case.





148. Install a new transaxle case oil seal.
149. Coat the lip of the seal with Multi-Purpose grease or equivalent.





150. Install a new transaxle oil seal in the transaxle case.
151. Coat the lip of the seal with Multi-Purpose grease or equivalent.





152. Using a press, install the underdrive roller bearing in the transaxle housing.





153. Notice: Refer to Fastener Notice in Service Precautions.

Install the roller bearing retainer with the bolt to the transaxle housing.
^ Tighten the bolt to 17 Nm (13 ft. lbs.).





154. Using a soft faced hammer, install the differential gear lube apply tube.
155. Using a soft faced hammer, install the transaxle apply tube in the transaxle housing.





156. Install the transaxle apply tube clamps and bolts in the transaxle housing.
^ Tighten the bolts to 5.5 Nm (49 inch lbs.).





157. Using a press, install the counterdriven gear roller bearing in the transaxle case.





158. Coat the new B-4 accumulator O-rings with T-IV automatic transmission fluid.
159. Install the O-rings on the accumulator piston.
160. Install accumulator piston and spring in the transaxle case.





161. Install the transmission case plate and gasket on the transaxle case.
162. Install the 2 bolts.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).





163. Apply Threadlocker 242 GM P/N 12345382 (Canadian P/N 10953459) or the equivalent to the 7 retaining screws.