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Home >> Suzuki >> 2006 >> Swift + >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle - AISIN (81-40LE) - Introduction (2 Of 2) >> Repair Instructions >> Transmission Assemble >> Assembly Procedure
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Assembly Procedure

    Fig 1: Screw Plugs, 4 O-Rings & Transaxle Rear Cover
    GM1245944Courtesy of GENERAL MOTORS CORP.
  1. Install 4 new O-rings to the 4 screw plugs.
    2. NOTE: Refer to Fastener Notice .
  2. Install the 4 screw plugs with the O-rings to the transaxle rear cover.

    Tighten:  Tighten the screw plugs to 7.4 N.m (65 lb in).

    3. Fig 2: Seal Rings & Transaxle Rear Cover
    GM1245946Courtesy of GENERAL MOTORS CORP.
  3. Install the 2 seal rings to the transaxle rear cover.
    4. Fig 3: Measuring Free Length Of O/D Brake Piston Return Spring Using The Vernier Calipers
    GM1245948Courtesy of GENERAL MOTORS CORP.
  4. Using the vernier calipers, measure the free length of the overdrive (O/D) brake piston return spring together with the spring seat.

    Specification:  The standard free length is 18.99 mm (0.7476 in).

    5. Fig 4: O-Rings & O/D Brake Piston
    GM1245947Courtesy of GENERAL MOTORS CORP.
  5. Coat 2 new O-rings (1) with automatic transaxle fluid (ATF). Install the O-rings to the O/D brake piston.
    6. Fig 5: O/D Brake Piston & ATF
    GM1245950Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not damage the O-rings of the O/D brake piston.
  6. Coat the O/D brake piston with ATF. Install the piston to the transaxle rear cover.
    7. Fig 6: Removing Snap Ring Using A Driver, DT 46451 & DT46454
    GM1245936Courtesy of GENERAL MOTORS CORP.
  7. Using DT 46451  (1), DT 46454  (2) and a driver, install the O/D brake return spring and snap ring to the transaxle rear cover. See Special Tools .
    8. Fig 7: Installing Side Bearing Outer Race & Transaxle Housing Using DT 46462 & DT 46465
    GM1245951Courtesy of GENERAL MOTORS CORP.
  8. Using DT 46462  (2) and DT 46465  (1), install a new side bearing outer race into the transaxle housing. See Special Tools .
    9. Fig 8: Driving In A Transaxle Housing Oil Seal Using A Hammer & DT 46471
    GM1245952Courtesy of GENERAL MOTORS CORP.
  9. Using DT 46471  (1) and a hammer, drive in a new transaxle housing oil seal. See Special Tools .

    Specification:  The oil seal depth is 3.1 mm (0.122 in).

    10. Fig 9: Oil Seal & Transaxle Housing
    GM1245931Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Press-fit the outer tapered roller bearing race until the race contacts the transaxle housing.
  10. Install a new outer tapered roller bearing race into the transaxle housing.
    11. Fig 10: No. 1 Transaxle Apply Pipe Clamp
    GM1245940Courtesy of GENERAL MOTORS CORP.
  11. Install the transaxle lube apply pipe and differential gear lube apply pipe to the transaxle housing.
  12. Install the No. 1 transaxle apply pipe clamp to the transaxle housing with the bolt.

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in).

    13. Fig 11: Oil Reservoir Lock Plate
    GM1245935Courtesy of GENERAL MOTORS CORP.
  13. Install the oil reservoir lock plate to the transaxle housing with the 3 bolts.

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in).

    14. Fig 12: Counter Driven Gear Outer Tapered Roller Bearing Race & Shim
    GM1245930Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: First install a shim of the same thickness as the original shim.
  14. Install the shim to the transaxle case.
  15. Install a new bearing outer race into the transaxle case.
    16. Fig 13: Driving In A Transaxle Case Oil Seal Using A Hammer & DT 46471
    GM1245949Courtesy of GENERAL MOTORS CORP.
  16. Using DT 47521  (1) and a hammer, drive in a new transaxle case oil seal. See Special Tools .

    Specifications:  The oil seal depth is 4.3 mm (0.169 in).

    17. Fig 14: Pressing In A New Outer Tapered Roller Bearing Race Using DT 46464 & DT 46465
    GM1245954Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: First install a shim of the same thickness as the original shim.
  17. Install the shim to the transaxle case.
    18. IMPORTANT: Press-fit the shim until the shim contacts the transaxle case.
  18. Using DT 46464  (2) and DT 46465  (1), press in a new outer tapered roller bearing race into the transaxle case. See Special Tools .
    19. Fig 15: No. 1 Transaxle Case Plate
    GM1245953Courtesy of GENERAL MOTORS CORP.
  19. Install the No. 1 transaxle case plate to the transaxle case with the bolt.

    Tighten:  Tighten the bolt to 9.8 N.m (87 lb in).

    20. Fig 16: Differential Gear & Transaxle Case
    GM1245956Courtesy of GENERAL MOTORS CORP.
  20. Install the differential gear to the transaxle case.
    21. Fig 17: Installing Transaxle Housing
    GM1245958Courtesy of GENERAL MOTORS CORP.
  21. Install the transaxle housing and hand tighten the 16 bolts of the transaxle housing.
  22. Tighten 8 or 9 bolts of the transaxle housing completely.

    Tighten:  Tighten the bolts to 29 N.m (22 lb ft).

    23. Fig 18: Turning The Differential Gear Assembly
    GM1245959Courtesy of GENERAL MOTORS CORP.
  23. Using DT 46461  , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle. See Special Tools .
    24. Fig 19: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
    GM1245955Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Note the measured value.
  24. Using DT 46461  and a small torque wrench, measure the preload of the differential gear. See Special Tools .
    25. Fig 20: Transaxle Housing & Counter Driven Gear
    GM1245968Courtesy of GENERAL MOTORS CORP.
  25. Remove the transaxle housing and install the counter driven gear.
    26. Fig 21: Installing Transaxle Housing
    GM1245958Courtesy of GENERAL MOTORS CORP.
  26. Install the transaxle housing and hand tighten the 16 bolts of the transaxle housing.
  27. Tighten 8 or 9 bolts of the transaxle housing completely.

    Tighten:  Tighten the bolts to 29 N.m (21 lb ft).

    28. Fig 22: Turning The Differential Gear Assembly
    GM1245959Courtesy of GENERAL MOTORS CORP.
  28. Using DT 46461  , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle. See Special Tools .
    29. Fig 23: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
    GM1245955Courtesy of GENERAL MOTORS CORP.
  29. Using DT 46461  and a small torque wrench, measure the preload of the differential gear. See Special Tools . From this value deduct the value measured previously. This new value is the preload of the counter driven gear.

    Specification: 

    • The preload for a new bearing is 0.33-0.76 N.m (3.21-6.77 lb in).
    • The preload for a used bearing is 0.17-0.38 N.m (1.48-3.39 lb in).

    30. IMPORTANT: When the preload is larger than the specification, select a thinner adjuster shim. When the preload is smaller than specification, select a thicker adjuster shim.
  30. If the preload of the counter driven gear does not satisfy the specification, select the adjuster shim from the table below and re-measure the value. Until the value is within the specification, repeat the procedure.
    31. Fig 24: Measuring The Free Length Of 1st & Reverse Brake Piston Return Spring Using The Vernier Calipers
    GM1245963Courtesy of GENERAL MOTORS CORP.
  31. Using the vernier calipers, measure the free length of the 1st and reverse brake piston return spring together with the spring seat.

    Specification:  The standard free length is 18.053 mm (0.71075 in).

    32. Fig 25: Sliding Surface Of Disc
    GM1245961Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
    • Before assembling the new discs, soak the discs in ATF for at least 15 minutes.
  32. Inspect the sliding surface of the disc, the plate and the flange of the 1st and reverse brake for wear or burn. Replace the parts, if necessary.
    33. Fig 26: O-Rings & 1st & Reverse Brake Piston
    GM1245934Courtesy of GENERAL MOTORS CORP.
  33. Coat 2 new O-rings (1) with ATF, install the O-rings to the 1st and reverse piston.
    34. Fig 27: 1st & Reverse Brake Piston
    GM1375541Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not damage the O-rings of the 1st and reverse brake piston.
  34. Install the 1st and reverse brake piston to the transaxle case.
    35. Fig 28: Return Spring & Transaxle Case
    GM1245964Courtesy of GENERAL MOTORS CORP.
  35. Install the return spring to the transaxle case.
    36. Fig 29: Plates, Discs & Flange
    GM1245965Courtesy of GENERAL MOTORS CORP.
  36. Install the 4 plates, the 4 discs and the flange in order: 2-1-2-1-2-1-2-1-3, where (2)=Plate, (1)=Disc, and (3)=Flange
    37. Fig 30: DT 46455, DT 46457, Snap Ring Of 1st & Reverse Brake
    GM1245938Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Verify that the snap ring is installed correctly in the groove of the transaxle case.
  37. Using DT 46457  (2) and DT 46455  (1), install the snap ring. See Special Tools .
    38. Fig 31: Measuring The 1st & Reverse Brake Piston Stroke Using A Dial Indicator
    GM1245966Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the piston stroke is non-standard, inspect the discs, the plates and the flange. The piston stroke is 0.6-1.3 mm (0.024-0.051 in).
  38. Using a dial indicator, measure the 1st and reverse brake piston stroke while applying and releasing 392-785 kPa (57-114 psi) of compressed air.
    39. Fig 32: DT 46460, DT 46455 & DT 46456
    GM1245967Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not apply excessive force to the transaxle case.
  39. Using DT 46460  (3), DT 46455  (2) and DT 46456  (1), install the counter drive gear. See Special Tools .
    40. Fig 33: Transaxle Housing & Counter Driven Gear
    GM1245968Courtesy of GENERAL MOTORS CORP.
  40. Coat a new oil seal with ATF.
  41. Install the oil seal to the transaxle case.

    Specification:  The oil seal depth is 0.75-1.25 mm (0.030-0.049 in).

    42. Fig 34: Parking Lock Rod & Manual Valve Lever
    GM1245921Courtesy of GENERAL MOTORS CORP.
  42. Install the parking lock rod to the manual valve lever.
    43. Fig 35: Spacer & Manual Valve Lever
    GM1245969Courtesy of GENERAL MOTORS CORP.
  43. Install a new spacer to the manual valve lever.
    44. Fig 36: Manual Valve Lever & Shaft
    GM1245970Courtesy of GENERAL MOTORS CORP.
  44. Install the manual valve lever shaft and the manual valve lever.
    45. Fig 37: Driving The Pin Using A Pin Punch & Hammer
    GM1245919Courtesy of GENERAL MOTORS CORP.
  45. Using a pin punch and hammer, drive in a new pin.
    46. Fig 38: Staking Spacer Through Small Hole
    GM1245971Courtesy of GENERAL MOTORS CORP.
  46. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
  47. Using a pin punch, stake the spacer through the small hole.
  48. Verify that the spacer does not turn.
    49. Fig 39: Bolt & Manual Detent Spring
    GM1245917Courtesy of GENERAL MOTORS CORP.
  49. Install the manual detent spring with the bolt.

    Tighten:  Tighten the bolt to 9.8 N.m (87 lb in).

    50. Fig 40: Parking Lock Pawl, Shaft & Torsion Spring
    GM1245916Courtesy of GENERAL MOTORS CORP.
  50. Install the parking lock shaft, the torsion spring and the parking lock pawl.
    51. Fig 41: Edge Of Torsion Spring
    GM1245972Courtesy of GENERAL MOTORS CORP.
  51. Verify that the edge of the torsion spring fits into the groove securely.
    52. Fig 42: Bolts & Parking Lock Pawl Bracket
    GM1245915Courtesy of GENERAL MOTORS CORP.
  52. Install the parking lock pawl bracket with the 2 bolts.

    Tighten:  Tighten the bolts to 7.4 N.m (65 lb in).

    53. Fig 43: DT 46460, DT 46455 & Planetary Ring Gear
    GM1245973Courtesy of GENERAL MOTORS CORP.
  53. Replace the planetary ring flange of the planetary ring gear.
  54. Using DT 46460  (2) and DT 46455  (1), install the planetary ring gear. See Special Tools .
    55. Fig 44: Counter Drive Gear & Parking Lock Pawl
    GM1245914Courtesy of GENERAL MOTORS CORP.
  55. Fix the counter drive gear with the parking lock pawl.
    56. Fig 45: Removing Planetary Ring Gear Nut Using DT 46472
    GM1245906Courtesy of GENERAL MOTORS CORP.
  56. Using DT 46472  (1), install a new nut. See Special Tools .

    Tighten:  Tighten the nut to 9.8 N.m (87 lb in).

    57. Fig 46: Turning The Counter Drive Gear Using A Wrench
    GM1245975Courtesy of GENERAL MOTORS CORP.
  57. Using a small torque wrench, turn the counter drive gear 100 turn per minute and measure the preload.

    Tighten:  Tighten the nut to 29 N.m (22 lb ft) or less.

    Specification:  When the preload is smaller than the specification, tighten the nut more and adjust the preload to 0.05-0.35 N.m (0.43-3.12 lb in).

  58. Stake the nut.
    59. Fig 47: Planetary Gear & Transaxle Case
    GM1245974Courtesy of GENERAL MOTORS CORP.
  59. Install the planetary gear to the transaxle case.
    60. Fig 48: Planetary Carrier Thrust Washer & Planetary Gear
    GM1245976Courtesy of GENERAL MOTORS CORP.
  60. Coat the planetary carrier thrust washer with petroleum jelly and install the washer onto the planetary gear.
    61. Fig 49: No. 2 One-Way Clutch & Transaxle Case
    GM1245977Courtesy of GENERAL MOTORS CORP.
  61. Install the No. 2 one-way clutch to the transaxle case.
    62. Fig 50: Verifying Planetary Gear Turns Freely
    GM1245979Courtesy of GENERAL MOTORS CORP.
  62. Verify that the planetary gear turns freely counterclockwise and locks clockwise.
    63. Fig 51: Anti-Rattle Clip, No. 2 One-Way Clutch Outer Race & Transaxle Case
    GM1245980Courtesy of GENERAL MOTORS CORP.
  63. Install the anti-rattle clip in the space between the No. 2 one-way clutch outer race and transaxle case. Push the anti-rattle clip in place until you hear the click.
    64. Fig 52: Measuring The Free Length Of 2nd Brake Piston Return Spring Using Vernier Calipers
    GM1245978Courtesy of GENERAL MOTORS CORP.
  64. Using vernier calipers, measure the free length of the 2nd brake piston return spring together with the spring seat.

    Specification:  The standard free length is 15.85 mm (0.6240 in).

    65. Fig 53: Disc
    GM1245981Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
    • Before assembling the new discs, soak the discs in ATF for at least 15 minutes.
  65. If the sliding surface of the disc, the plate and the flange of 2nd brake are worn or burnt, replace the parts.
    66. Fig 54: Flange, Discs & Plates
    GM1245983Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Install the snap ring in the groove of the transaxle case correctly.
  66. Install the flange, 2 discs and 2 plates in order: 2-1-3-1-3, where (1)=Disc, (2)=Flange, and (3)=Plate.
  67. Install the 2nd brake return spring.
    68. Fig 55: O-Rings & 2nd Brake Piston
    GM1245910Courtesy of GENERAL MOTORS CORP.
  68. Coat 2 new O-rings (1) with ATF and install the O-rings to the 2nd brake piston.
    69. Fig 56: 2nd Brake Piston & 2nd Brake Clutch Cylinder
    GM1245984Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not damage the O-rings.
  69. Install the 2nd brake piston into the 2nd brake clutch cylinder.
    70. Fig 57: 2nd Brake Clutch Cylinder & Transaxle Case
    GM1245982Courtesy of GENERAL MOTORS CORP.
  70. Install the 2nd brake clutch cylinder to the transaxle case.
    71. Fig 58: DT 46455 & DT 46458
    GM1245908Courtesy of GENERAL MOTORS CORP.
  71. Using DT 46455  (1) and DT 46458  (2), compress the 2nd brake piston return spring. See Special Tools .
    72. IMPORTANT: Install the snap ring in the groove of the transaxle case correctly.
  72. Using the screwdriver, install the snap ring.
    73. Fig 59: Thrust Bearing Race & Front Planetary Sun Gear
    GM1245985Courtesy of GENERAL MOTORS CORP.
  73. Coat the thrust bearing race with petroleum jelly and install the race onto the front planetary sun gear.

    Specification: 

    • The race inner diameter is 19.3 mm (0.760 in).
    • The race outer diameter is 29.0 mm (1.142 in).

    74. Fig 60: Front Planetary Sun Gear & Thrust Bearing Race
    GM1245907Courtesy of GENERAL MOTORS CORP.
  74. Install the front planetary sun gear to the transaxle case.
    75. Fig 61: 1-Way Clutch Assembly, Thrust Washer & Rear Planetary Sun Gear
    GM1245904Courtesy of GENERAL MOTORS CORP.
  75. Install the thrust washer and the one-way clutch assembly to the rear planetary sun gear.
    76. Fig 62: Thrust Bearing Race & Rear Planetary Sun Gear
    GM1245986Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Verify the direction of the bearing.
  76. Coat the thrust bearing race with petroleum jelly and install the race onto the rear planetary sun gear and the one-way clutch assembly.

    Specification: 

    • The bearing inner diameter is 42.5 mm (1.673 in).
    • The bearing outer diameter is 57.5 mm (2.264 in).

    77. Fig 63: Rear Planetary Sun Gear & 1-Way Clutch Assembly
    GM1245900Courtesy of GENERAL MOTORS CORP.
  77. Install the rear planetary sun gear and the one-way clutch assembly to the transaxle case.
    78. Fig 64: Thrust Bearing Race & Transaxle Case
    GM1245987Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Verify the direction of the race.
  78. Coat the thrust bearing race with petroleum jelly and install the race onto the transaxle case.

    Specification: 

    • The race inner diameter is 34.95 mm (1.3760 in).
    • The race outer diameter is 45.50 mm (1.7913 in).

    79. Fig 65: Thrust Needle Roller Bearing & Forward Clutch Hub
    GM1245988Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Verify the direction of the bearing.
  79. Coat the thrust needle roller bearing with petroleum jelly and install the bearing onto the forward clutch hub.

    Specification: 

    • The bearing inner diameter is 33.3 mm (1.311 in).
    • The bearing outer diameter is 46.5 mm (1.831 in).

    80. Fig 66: Forward Clutch Hub & Transaxle Case
    GM1245886Courtesy of GENERAL MOTORS CORP.
  80. Install the forward clutch hub to the transaxle case.
    81. Fig 67: Thrust Bearing Race & Forward Clutch Hub
    GM1245990Courtesy of GENERAL MOTORS CORP.
  81. Coat the thrust bearing race with petroleum jelly and install the race onto the forward clutch hub.

    Specification: 

    • The race inner diameter is 19.3 mm (0.760 in).
    • The race outer diameter is 30.6 mm (1.205 in).

    82. Fig 68: Thrust Needle Roller Bearing, Race & Forward/Reverse Clutch Assembly
    GM1245888Courtesy of GENERAL MOTORS CORP.
  82. Install the thrust bearing race and thrust needle roller bearing to the forward and reverse clutch assembly.

    Specification: 

    • The race inner diameter is 18.1 mm (0.713 in).
    • The race outer diameter is 28.2 mm (1.110 in).
    • The bearing inner diameter is 18.1 mm (0.713 in).
    • The bearing outer diameter is 29.6 mm (1.165 in).

    83. Fig 69: Forward/Reverse Clutch Assembly & Transaxle Case
    GM1245989Courtesy of GENERAL MOTORS CORP.
  83. Install the forward and reverse clutch assembly to the transaxle case.
    84. Fig 70: Sliding Surface Of Disc
    GM1245961Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • If the lining of the disc is peeling off or discolored, or even if the part of the printed mark is defaced, replace all discs.
    • Before assembling new discs, soak the discs in ATF for at least 15 minutes.
  84. If the sliding surface of the disc, the plate and the flange of 2nd coast and O/D brake are worn or burnt, replace the components.
    85. Fig 71: Installing Snap Ring To Transaxle Case Using A Screwdriver
    GM1245991Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Install the snap ring in the groove of the transaxle case correctly.
  85. Using a screwdriver, install the snap ring to the transaxle case.
    86. Fig 72: O/D Brake Flange, Discs & Plates
    GM1245889Courtesy of GENERAL MOTORS CORP.
  86. Install the flange, 2 discs and 2 plates to the transaxle case in the following order: 3-2-3-2-1, where (3)=Plate, (2)=-Disc, and (1)=Flange.
  87. Clean the connected part the transaxle case and the transaxle rear cover.
    88. Fig 73: Measuring The Distance Between 2nd Coast & O/D Brake Flange Using Vernier Calipers
    GM1245992Courtesy of GENERAL MOTORS CORP.
  88. Place a straight edge on the transaxle case and measure the distance between the 2nd coast and the O/D brake flange and the straight edge using vernier calipers (a).
    89. Fig 74: Measuring The Distance Between Transaxle Rear Cover & Straight Edge Using Vernier Calipers
    GM1245994Courtesy of GENERAL MOTORS CORP.
  89. Place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and the straight edge using vernier calipers (a).
  90. Calculate the piston stroke value using the following formula. Select and install a flange which satisfies the piston stroke value.
    91. Fig 75: Apply Gaskets & Transaxle Rear Cover
    GM1245893Courtesy of GENERAL MOTORS CORP.
  91. Install 4 new apply gaskets to the transaxle rear cover.
    92. Fig 76: Thrust Needle Roller Bearing & Forward/Reverse Clutch Assembly
    GM1245993Courtesy of GENERAL MOTORS CORP.
  92. Coat the thrust needle roller bearing with petroleum jelly and install the bearing onto the forward and reverse clutch assembly.

    Specification: 

    • The bearing inner diameter is 43.2 mm (1.701 in).
    • The bearing outer diameter is 62.0 mm (2.441 in).

  93. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle rear cover or transaxle case.
    94. Fig 77: Transaxle Rear Cover
    GM1245996Courtesy of GENERAL MOTORS CORP.
  94. Apply a formed in place gasket (FIPG) to the transaxle rear cover.

    Specification:  The FIPG three bond 1281, or equivalent, seal bend width is 1.2 mm (0.047 in).

    95. Fig 78: Transaxle Rear Cover, Transaxle Case & Bolts
    GM1245995Courtesy of GENERAL MOTORS CORP.
  95. Install the transaxle rear cover to the transaxle case with 9 bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    96. Fig 79: Counter Driven Gear Assembly & Transaxle Case
    GM1245890Courtesy of GENERAL MOTORS CORP.
  96. Install the counter driven gear assembly to the transaxle case.
    97. Fig 80: Differential Gear Assembly & Transaxle Case
    GM1245884Courtesy of GENERAL MOTORS CORP.
  97. Install the differential gear assembly to the transaxle case.
    98. Fig 81: Direct Clutch Hub & Transaxle Case
    GM1245998Courtesy of GENERAL MOTORS CORP.
  98. Install the direct clutch hub to the transaxle case.
    99. Fig 82: Thrust Bearing Race, Thrust Needle Roller Bearing & Transaxle Case
    GM1245997Courtesy of GENERAL MOTORS CORP.
  99. Install the thrust bearing race and the thrust needle roller bearing to the transaxle case.

    Specification: 

    • The race inner diameter is 20.5 mm (0.807 in).
    • The race outer diameter is 32.6 mm (1.283 in).
    • The bearing inner diameter is 17.8 mm (0.701 in).
    • The bearing outer diameter is 30.2 mm (1.189 in).

    100. Fig 83: Direct Clutch Assembly & Transaxle Case
    GM1245897Courtesy of GENERAL MOTORS CORP.
  100. Install the clutch assembly to the transaxle case.
    101. Fig 84: Apply Gasket
    GM1245899Courtesy of GENERAL MOTORS CORP.
  101. Install the new apply gasket.
    102. Fig 85: Oil Pump & Input Shaft
    GM1246000Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Verify the direction of the bearing.
  102. Install the thrust needle roller bearing to the transaxle case.
  103. Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transaxle case.
    104. Fig 86: Oil Pump & Bolts
    GM1245881Courtesy of GENERAL MOTORS CORP.
  104. Install the 6 oil pump bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    105. Fig 87: Measuring The Input Shaft End Play Using A Dial Indicator
    GM1245882Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the end play is not as specified, select and replace the thrust needle roller bearing.
  105. Measure the end play in axial direction.

    Specification: 

    • The end play is 0.3-0.9 mm (0.012-0.035 in).
    • The bearing inner diameter is 32.5 mm (1.280 in).
    • The bearing outer diameter is 48.5 mm (1.909 in).
    • The bearing thickness is 4.21 mm (0.1657 in).
    • The bearing inner diameter is 32.9 mm (1.295 in).
    • The bearing outer diameter is 48.5 mm (1.909 in).
    • The bearing thickness is 3.62 mm (0.1425 in).

    106. Fig 88: Confirming Input Shaft Rotates Smoothly
    GM1245999Courtesy of GENERAL MOTORS CORP.
  106. Confirm that the input shaft rotates smoothly.
    107. Fig 89: FIPG & Transaxle Housing
    GM1246001Courtesy of GENERAL MOTORS CORP.
  107. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle housing or the transaxle case.
  108. Apply a formed in place gasket (FIPG) to the transaxle housing.

    Specification:  FIPG: Three bond 1281 or equivalent, seal bend width is 1.2 mm (0.047 in).

    109. Fig 90: Transaxle Housing, Transaxle Case & Bolts
    GM1246002Courtesy of GENERAL MOTORS CORP.
  109. Install the transaxle housing to the transaxle case with 16 bolts.

    Tighten:  Tighten the bolts to 29 N.m (22 lb ft).

  110. Apply seal packing or equivalent to the 3 bolts.
    111. Fig 91: O-Ring & Transaxle Wire
    GM1245876Courtesy of GENERAL MOTORS CORP.
  111. Coat a new O-ring (1) with ATF, install the O-ring to the transaxle wire.
    112. Fig 92: Transaxle Wire & Transaxle Case
    GM1245877Courtesy of GENERAL MOTORS CORP.
  112. Install the transaxle wire to the transaxle case with the bolt.

    Tighten:  Tighten the bolt to 5.4 N.m (48 lb in).

    113. Fig 93: O-Rings, ATF & Pistons
    GM1246003Courtesy of GENERAL MOTORS CORP.
  113. Coat new 6 O-rings with ATF and install the O-rings to the pistons (1,2,3).
  114. Coat the 3 springs and 3 accumulator pistons with ATF and install the components to the holes.
    115. Fig 94: Apply Gasket
    GM1245857Courtesy of GENERAL MOTORS CORP.
  115. Coat a new apply gasket with ATF and install the gasket to the transaxle case.
    116. Fig 95: Brake Drum Gasket
    GM1245885Courtesy of GENERAL MOTORS CORP.
  116. Coat a new brake drum gasket with ATF and install the gasket to the transaxle case.
    117. Fig 96: Check Valve & Spring
    GM1245870Courtesy of GENERAL MOTORS CORP.
  117. Install the spring and the check valve.
    118. Fig 97: Manual Valve Control Rod & Manual Valve Lever
    GM1246004Courtesy of GENERAL MOTORS CORP.
  118. Connect the manual valve control rod to the manual valve lever as shown in the illustration.
    119. Fig 98: Valve Body Assembly
    GM1245868Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When installing the valve body to the transaxle case, do not let each of the accumulator pistons incline. When installing the valve body to the transaxle case, do not hold the solenoids.
  119. Install the valve body assembly to the transaxle case.

    Tighten:  Tighten the bolts to 11 N.m (97 lb in).

    120. Fig 99: Solenoid Connectors
    GM1245869Courtesy of GENERAL MOTORS CORP.
  120. Connect the transaxle wire connector and harness to the valve body assembly.
  121. Connect the 5 connectors.
    1. The lock-up control solenoid (5)
    2. The pressure control solenoid (1)
    3. The No. 2 shift solenoid (2)
    4. The No. 1 shift solenoid (3)
    5. The timing solenoid (4)
    122. IMPORTANT: Verify that the transaxle wire does not come out from the oil pan installations surface.
  122. Install the TFT sensor with a clamp.
    123. Fig 100: Gasket
    GM1245867Courtesy of GENERAL MOTORS CORP.
  123. Install a new gasket to the oil strainer.
    124. Fig 101: Oil Strainer
    GM1245866Courtesy of GENERAL MOTORS CORP.
  124. Install the oil strainer to the valve body with 3 bolts.

    Tighten:  Tighten the bolts to 9.8 N.m (87 lb in).

    125. Fig 102: Magnets & Oil Pan
    GM1246005Courtesy of GENERAL MOTORS CORP.
  125. Install 2 magnets in the oil pan.
    126. Fig 103: Oil Pan & Gasket
    GM1245862Courtesy of GENERAL MOTORS CORP.
  126. Install a new gasket to the oil pan and install the oil pan to the transaxle case with 18 bolts.

    Tighten:  Tighten the bolts to 7 N.m (62 lb in).

    127. Fig 104: OSS Sensor & Bolts
    GM1245864Courtesy of GENERAL MOTORS CORP.
  127. Install the output shaft speed (OSS) sensor.

    Tighten:  Tighten the bolt to 7.4 N.m (65 lb in).

    128. Fig 105: ISS Sensor & Bolts
    GM1245863Courtesy of GENERAL MOTORS CORP.
  128. Install the No. 1 breather plug.
  129. Install the input shaft speed (ISS) sensor with the bolt.

    Tighten:  Tighten the bolt to the 5.4 N.m (48 lb in).

    130. Fig 106: Screw Plug & Transaxle Case
    GM1245865Courtesy of GENERAL MOTORS CORP.
  130. Coat the new O-ring with ATF and install the O-ring to the screw plug.
  131. Install the screw plug to the transaxle case.

    Tighten:  Tighten the bolts to 7.4 N.m (65 lb in).

    132. Fig 107: Unions & Transaxle Case
    GM1245859Courtesy of GENERAL MOTORS CORP.
  132. Coat 2 new O-rings with ATF and install the O-rings to the unions.
  133. Install the 2 unions to the transaxle case.

    Tighten:  Tighten the unions to 25 N.m (18 lb ft).

    134. Fig 108: PNP Switch & Manual Valve Lever Shaft
    GM1245824Courtesy of GENERAL MOTORS CORP.
  134. Install the PNP switch to the manual valve lever shaft and temporarily install the 2 adjusting bolts.
  135. Install a new lock washer and nuts.

    Tighten:  Tighten the nuts to 12 N.m (106 lb in).

    136. Fig 109: Control Lever
    GM1246006Courtesy of GENERAL MOTORS CORP.
  136. Temporarily install the control lever.
    137. Fig 110: Turning PNP Switch Lever
    GM1245822Courtesy of GENERAL MOTORS CORP.
  137. Turn the lever counterclockwise until the lever stops, then turn clockwise 2 notches.
  138. Remove the control lever.
    139. Fig 111: Aligning Groove With Neutral Basic Line
    GM1245808Courtesy of GENERAL MOTORS CORP.
  139. Align the groove with the neutral basic line. Tighten 2 bolts.

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in).

    140. Fig 112: Staking The Nut With Lock Washer Using A Screwdriver
    GM1245810Courtesy of GENERAL MOTORS CORP.
  140. Using a screwdriver, stake the nut with the lock washer.
    141. Fig 113: PNP Switch Control Lever, Washer & Nut
    GM1245825Courtesy of GENERAL MOTORS CORP.
  141. Install the control lever, the washer and the nut.

    Tighten:  Tighten the nut to 12 N.m (106 lb in).

    142. Fig 114: Torque Converter & Transaxle
    GM1246008Courtesy of GENERAL MOTORS CORP.
  142. Install the torque converter (2) to the transaxle.
  143. Measure the installation depth of the torque converter.

    Specification:  The standard value is 11.1 mm (0.44 in).

  144. If the measured value is beyond the standard value, readjust the torque converter within the specified value.
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