GM Service Manual Online
For 1990-2009 cars only

Tools Required

J 35405 Differential Preload Wrench


    Object Number: 908190  Size: SH
  1. Remove the breather plug, O-ring and hose from the transaxle case.
  2. Remove the breather plug.
  3. Remove the nut, washer and control shift lever from the transaxle.
  4. Pry up the lock tab on the washer, then remove the retaining nut.
  5. Remove the 2 PNP switch retaining bolts, then remove the switch from the transaxle.

  6. Object Number: 908194  Size: SH
  7. Remove the 2 oil cooler unions from the transaxle.
  8. Remove the O-rings from the unions.
  9. Important: Do not turn the transaxle over to remove the oil pan as it will contaminate the valve body with foreign material within the oil pan.


    Object Number: 908200  Size: SH
  10. Remove the oil pan retaining bolts, then the oil pan.
  11. Place the transaxle on wooden blocks to prevent damage to the pipes.

  12. Object Number: 908204  Size: SH
  13. Remove the 3 oil filter retaining bolts, then the oil filter and gasket.

  14. Object Number: 908207  Size: SH
  15. Remove the bolt, manual detent spring and spring cover.

  16. Object Number: 908210  Size: SH
  17. Disconnect the solenoid connectors.

  18. Object Number: 908213  Size: SH
  19. Remove the 17 valve body retaining bolts.

  20. Object Number: 908221  Size: SH
  21. Disconnect the connecting rod from the manual valve.
  22. Remove the valve body from the transaxle case.

  23. Object Number: 908223  Size: SH
  24. Remove the transaxle wiring harness retaining bolt.

  25. Object Number: 908226  Size: SH
  26. Remove the wiring harness from the transaxle case.
  27. Remove the O-ring from the harness connector.

  28. Object Number: 908228  Size: SH
  29. Remove the check ball body and spring from the transaxle case.

  30. Object Number: 908231  Size: SH
  31. Remove the governor apply gasket from the transaxle case.

  32. Object Number: 908257  Size: SH
  33. Remove the brake drum gasket from the transaxle case.

  34. Object Number: 908259  Size: SH
  35. Cover the B-2 accumulator piston with a shop towel.
  36. Using compressed air at low pressure 98 kPa (14 psi) push out the B-2 accumulator piston from the transaxle case.
  37. Remove the 2 O-rings from the accumulator piston.

  38. Object Number: 908260  Size: SH
  39. Cover the C-2 accumulator piston with a shop towel.
  40. Using compressed air at low pressure 98 kPa (14 psi) push out the C-2 accumulator piston from the transaxle case.
  41. Remove the 2 O-rings from the accumulator piston.

  42. Object Number: 908261  Size: SH
  43. Cover the C-1 accumulator piston with a shop towel.
  44. Using compressed air at low pressure 98 kPa (14 psi) push out the C-1 accumulator piston from the transaxle case.
  45. Remove the 2 O-rings from the accumulator piston.

  46. Object Number: 908262  Size: SH
  47. Cover the C-3 accumulator piston with a shop towel.
  48. Using compressed air at low pressure 98 kPa (14 psi) push out the C-3 accumulator piston from the transaxle case.
  49. Remove the 2 O-rings from the accumulator piston.

  50. Object Number: 908264  Size: SH
  51. Using a screwdriver and a hammer, unstake the spacer then remove the spacer from the transaxle case.

  52. Object Number: 908265  Size: SH

    Important: Drive out the spring pin slowly so that it does not fall into the transaxle case.

  53. Using a punch and hammer, remove the spring pin.

  54. Object Number: 908266  Size: SH
  55. Remove the retainer spring.

  56. Object Number: 908268  Size: SH
  57. Slide out the manual valve lever shaft, then remove the manual valve lever assembly and washer plate.

  58. Object Number: 908272  Size: SH
  59. Using a screwdriver, remove the manual valve lever shaft oil seal.

  60. Object Number: 908275  Size: SH
  61. Remove the 17 transaxle case bolts.
  62. Separate the transaxle housings.

  63. Object Number: 908282  Size: SH
  64. Remove the differential assembly from the transaxle case.
  65. Remove the transaxle case plate bolt and transaxle case plate from the transaxle housing.

  66. Object Number: 908285  Size: SH
  67. Remove the governor apply gasket from the transaxle case.

  68. Object Number: 908296  Size: SH
  69. Remove the 6 oil pump assembly retaining bolts.

  70. Object Number: 908300  Size: SH
  71. Lift out the oil pump assembly from the transaxle case.

  72. Object Number: 908304  Size: SH
  73. Using a screwdriver, remove the O-ring from the oil pump.

  74. Object Number: 908315  Size: SH
  75. Remove the bolt and the apply tube clamp from the transaxle case.

  76. Object Number: 908317  Size: SH
  77. Remove the governor pressure tube from the transaxle case.

  78. Object Number: 908320  Size: SH
  79. Apply a index mark to the piston at the point where it meets the transaxle case.

  80. Object Number: 908357  Size: SH

    Important: If the piston stroke is not within 1.5-3.0 mm (0.059-0.118 in). Inspect the brake band.

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

  82. Object Number: 908570  Size: SH
  83. Remove the 2nd coast brake piston snap ring.

  84. Object Number: 908571  Size: SH
  85. Using compressed air at low pressure 98 kPa (14 psi) push out the cover into a shop towel.

  86. Object Number: 908575  Size: SH
  87. Remove the cover, 2nd coast brake piston assembly and spring.
  88. Remove the 2 O-rings from the coast brake cover.

  89. Object Number: 908579  Size: SH
  90. Remove the direct clutch with the forward clutch from the transaxle case.

  91. Object Number: 908583  Size: SH
  92. Remove the direct clutch from the forward clutch.

  93. Object Number: 908588  Size: SH
  94. Remove the clutch drum thrust washer and the 2 thrust needle roller bearings from the forward clutch.

  95. Object Number: 908593  Size: SH
  96. Pull out the 2nd coast brake band pin.
  97. Remove the 2nd coast brake band assembly from the transaxle case.

  98. Object Number: 908597  Size: SH
  99. Inspect the 2nd coast brake band assembly. If peeled, discolored, or if a part of the printed numbers (1)  are defaced, replace the 2nd coast brake band assembly.

  100. Object Number: 908604  Size: SH
  101. Remove the front planetary ring gear assembly from the transaxle case.

  102. Object Number: 908611  Size: SH
  103. Remove the thrust bearing and thrust bearing race from the front planetary ring gear assembly.

  104. Object Number: 908615  Size: SH
  105. Remove the front planetary gear assembly and the thrust bearing race from the transaxle case.

  106. Object Number: 908622  Size: SH
  107. Remove the thrust bearing and the thrust bearing race from the front planetary gear assembly.

  108. Object Number: 908629  Size: SH
  109. Using a feeler gage, measure the planetary pinion gear thrust clearance. If clearance exceeds 0.5 mm (0.020 in), replace the front planetary gear assembly.

  110. Object Number: 908633  Size: SH
  111. Remove the planetary sun gear sub-assembly with the sun gear input drum and planetary thrust washer from the transaxle case.

  112. Object Number: 908634  Size: SH
  113. Remove the 1 way clutch assembly from the transaxle case.

  114. Object Number: 908636  Size: SH
  115. Hold the sun gear (1) and turn the hub (4). The hub should turn freely clockwise (3) and should lock if turned counterclockwise (2).

  116. Object Number: 908639  Size: SH
  117. Using compressed air, check that the 2nd brake piston moves smoothly.

  118. Object Number: 908644  Size: SH
  119. Remove the bolt and brake band guide plate retainer and the 2nd coast brake band guide plate from the transaxle case.

  120. Object Number: 908649  Size: SH
  121. Using a screwdriver, remove the snap ring from the transaxle case.

  122. Object Number: 908655  Size: SH
  123. Remove the 2nd brake piston return spring assembly from the transaxle case.

  124. Object Number: 908658  Size: SH
  125. Remove the 2nd brake piston return spring assembly from the transaxle.

  126. Object Number: 908662  Size: SH
  127. Remove the plates, 2nd brake clutch disc and flange from the transaxle case.

  128. Object Number: 908664  Size: SH
  129. Check the 2nd brake clutch discs. If the sliding surfaces of the discs, plates and flanges are worn, discolored, or if a part of the printed numbers (1) are defaced, replace all the discs and plates.

  130. Object Number: 908670  Size: SH
  131. Using 2 screwdrivers, remove the snap ring from the transaxle case.

  132. Object Number: 908688  Size: SH
  133. Remove the 1 way clutch assembly and the rear planetary gear assembly with the 2 planetary carrier thrust washers from the transaxle case.

  134. Object Number: 908690  Size: SH
  135. Remove the 2 planetary carrier thrust washers from the rear planetary gear assembly.

  136. Object Number: 908695  Size: SH
  137. Remove the thrust bearing and thrust bearing race from the transaxle case.

  138. Object Number: 908698  Size: SH
  139. Using a feeler gage, measure the rear planetary pinion gear thrust clearance. If clearance exceeds 0.5 mm (0.020 in), replace the rear planetary gear assembly.

  140. Object Number: 908701  Size: SH
  141. Using a feeler gage, measure the first and reverse brake pack clearance. If clearance exceeds 2.25 mm (0.0886 in), check the disc.

  142. Object Number: 908705  Size: SH
  143. Using a screwdriver, remove the snap ring from the transaxle case.

  144. Object Number: 908709  Size: SH
  145. Remove the flange, plates and 1st and reverse brake clutch discs from the transaxle case.

  146. Object Number: 908717  Size: SH
  147. 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.

  148. Object Number: 908725  Size: SH
  149. Using a press, slightly compress the return spring until the snap ring is free from the return spring.

  150. Object Number: 908728  Size: SH
  151. Using snap ring pliers, remove the snap ring.

  152. Object Number: 908734  Size: SH
  153. Using compressed air at low pressure 98 kPa (14 psi) push out the 1st and reverse brake piston from the transaxle case.

  154. Object Number: 908740  Size: SH
  155. Using a screwdriver, remove the 2 O-rings from the 1st and reverse brake piston.

  156. Object Number: 908740  Size: SH
  157. Remove the 13 bolts from the transaxle case.

  158. Object Number: 908743  Size: SH
  159. Using a soft faced hammer, tap the rear transaxle case cover to remove the rear case from the transaxle case.

  160. Object Number: 908744  Size: SH
  161. Using a punch and hammer, unstake the counterdrive gear nut.

  162. Object Number: 908746  Size: SH
  163. Remove the counterdrive gear nut.

  164. Object Number: 908752  Size: SH
  165. Remove the intermediate shaft sub-assembly from the transaxle case.

  166. Object Number: 908755  Size: SH
  167. Using a press, remove the counterdrive gear (1) from the transaxle case.
  168. Remove the snap ring from the counterdrive gear bearing.
  169. Remove the counterdrive gear bearing from the counterdrive gear.

  170. Object Number: 908760  Size: SH
  171. Using a punch and hammer, unstake the counterdriven gear nut.

  172. Object Number: 908781  Size: SH
  173. While holding the counter shaft assembly (1), remove the counterdriven gear nut.
  174. Using a suitable puller, remove the counterdriven gear.

  175. Object Number: 908787  Size: SH
  176. Remove the thrust bearing from the transaxle case.

  177. Object Number: 908801  Size: SH
  178. Pull out the counter shaft from the transaxle case.

  179. Object Number: 908872  Size: SH
  180. Remove the needle bearing from the counter shaft assembly.

  181. Object Number: 908879  Size: SH
  182. Install a dial indicator (1) on the underdrive clutch piston.

  183. Object Number: 908888  Size: SH

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

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

  185. Object Number: 908894  Size: SH
  186. Remove the underdrive clutch assembly from the transaxle case.
  187. Remove the underdrive 1 way clutch retainer from the transaxle case.

  188. Object Number: 908915  Size: SH
  189. 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).

  190. Object Number: 908919  Size: SH
  191. Remove the 1 way clutch assembly and the underdrive clutch drum thrust washer (1) from the underdrive clutch drum.

  192. Object Number: 908926  Size: SH
  193. Remove the 2 overdrive clutch drum oil seal rings from the transaxle case.

  194. Object Number: 908931  Size: SH
  195. Install a dial indicator on the underdrive brake pack.
  196. Important: If the clearance is not within 1.15-1.97 mm (0.0453-0.0766 in). Inspect the discs.

  197. While applying compressed air, measure the pack clearance.

  198. Object Number: 908938  Size: SH
  199. Using a press, compress the flange until the snap ring is accessible.
  200. Using a screwdriver, remove the underdrive clutch flange snap ring from the transaxle case.

  201. Object Number: 909090  Size: SH
  202. Remove the flange, plates and underdrive clutch discs.

  203. Object Number: 909096  Size: SH
  204. 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.

  205. Object Number: 909099  Size: SH
  206. Remove the underdrive brake return spring sub-assembly from the transaxle case.

  207. Object Number: 909103  Size: SH
  208. Using compressed air at low pressure 98 kPa (14 psi) push out the underdrive brake piston from the transaxle case into a shop towel.

  209. Object Number: 908738  Size: SH
  210. Using a screwdriver, remove the 2 O-rings from the underdrive brake piston.

  211. Object Number: 909107  Size: SH
  212. Remove the 2 bolts, pawl stopper plate, torsion spring and spring guide sleeve from the transaxle case.

  213. Object Number: 909111  Size: SH
  214. Remove the bolt and pawl shaft clamp from the transaxle case.

  215. Object Number: 909114  Size: SH
  216. Remove the parking lock pawl shaft and parking lock pawl from the transaxle case.

  217. Object Number: 909118  Size: SH
  218. Remove the spring guide sleeve from the transaxle case.

  219. Object Number: 909119  Size: SH
  220. Remove the cam guide sleeve from the transaxle case.

  221. Object Number: 909124  Size: SH
  222. Using a TORX® bit, remove the 7 screws.

  223. Object Number: 909131  Size: SH
  224. Remove the 2 bolts.
  225. Remove the transmission case plate No. 2 and the case plate gasket from the transaxle case.

  226. Object Number: 909135  Size: SH
  227. Remove the B-4 accumulator piston and spring from the transaxle case.
  228. Remove the 2 O-rings from the piston.
  229. Remove the bolt and the transmission case plate No.3 from the transaxle case.

  230. Object Number: 909139  Size: SH
  231. Using a suitable puller, remove the counterdriven gear roller bearing from the transaxle case.

  232. Object Number: 909143  Size: SH
  233. Remove the bolts and transaxle apply tube clamps from the transaxle case.

  234. Object Number: 909231  Size: SH
  235. Using a screwdriver, remove the lube apply tube from the transaxle case.
  236. Using a screwdriver, remove the differential gear apply tube from the transaxle case.

  237. Object Number: 909232  Size: SH
  238. Remove the bolt and the underdrive roller bearing retainer from the transaxle case.

  239. Object Number: 909235  Size: SH
  240. Using a puller, remove the roller bearing from the transaxle housing.

  241. Object Number: 909248  Size: SH
  242. Using a screwdriver, remove the housing oil seal from the transaxle case.

  243. Object Number: 909285  Size: SH
  244. Using a screwdriver, remove the transaxle case oil seal from the transaxle case.
  245. Using a bearing puller, remove the front drive pinion roller bearing from the differential case.
  246. Using a bearing puller, remove the rear drive pinion roller bearing from the differential case.

  247. Object Number: 909291  Size: SH
  248. Using a press, drive out the front pinion front roller bearing outer race.

  249. Object Number: 909321  Size: SH
  250. Drive out the front drive pinion rear roller bearing outer race and adjusting shim from the transaxle case.

  251. Object Number: 909336  Size: SH
  252. Using a press, install a new front drive pinion rear roller bearing on the differential case.

  253. Object Number: 909344  Size: SH
  254. Place the adjusting shim in the transaxle case.
  255. Using a press, install a new front drive pinion rear roller bearing outer race in the transaxle case.

  256. Object Number: 909353  Size: SH
  257. Install the speedometer drive gear on the differential case.

  258. Object Number: 909370  Size: SH
  259. Using a press, install a new front drive pinion front roller bearing in the transaxle case.

  260. Object Number: 909375  Size: SH
  261. Using a press, install a new front drive pinion front roller bearing outer race in the transaxle case.

  262. Object Number: 909407  Size: SH
  263. Install a new transaxle case oil seal.
  264. Coat the lip of the seal with Multi-Purpose grease or equivalent.

  265. Object Number: 909411  Size: SH
  266. Install a new transaxle oil seal in the transaxle case.
  267. Coat the lip of the seal with Multi-Purpose grease or equivalent.

  268. Object Number: 909415  Size: SH
  269. Using a press, install the underdrive roller bearing in the transaxle housing.
  270. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 909418  Size: SH
  271. Install the roller bearing retainer with the bolt to the transaxle housing.
  272. Tighten
    Tighten the bolt to 17 N·m (13 lb ft).


    Object Number: 909423  Size: SH
  273. Using a soft faced hammer, install the differential gear lube apply tube.
  274. Using a soft faced hammer, install the transaxle apply tube in the transaxle housing.

  275. Object Number: 909426  Size: SH
  276. Install the transaxle apply tube clamps and bolts in the transaxle housing.
  277. Tighten
    Tighten the bolts to 5.5 N·m (49 lb in).


    Object Number: 909437  Size: SH
  278. Using a press, install the counterdriven gear roller bearing in the transaxle case.

  279. Object Number: 909135  Size: SH
  280. Coat the new B-4 accumulator O-rings with T-IV automatic transmission fluid.
  281. Install the O-rings on the accumulator piston.
  282. Install accumulator piston and spring in the transaxle case.

  283. Object Number: 909131  Size: SH
  284. Install the transmission case plate and gasket on the transaxle case.
  285. Install the 2 bolts.
  286. Tighten
    Tighten the bolts to 10 N·m (7 lb ft).


    Object Number: 909124  Size: SH
  287. Apply Threadlocker 242 GM P/N 12345382 (Canadian P/N 10953459) or the equivalent to the 7 retaining screws.
  288. Using a TORX® bit, install the screws.
  289. Tighten
    Tighten the screws to 10 N·m (7 lb  ft).


    Object Number: 909119  Size: SH
  290. Install the cam guide sleeve in the transaxle case.

  291. Object Number: 909118  Size: SH
  292. Install the spring guide sleeve with the protruding portion facing up.

  293. Object Number: 909448  Size: SH
  294. Place the pawl stopper plate on the protruding portion of the lock sleeve in the transaxle case.

  295. Object Number: 909452  Size: SH
  296. Install the spring guide sleeve and torsion spring with the 2 bolts.
  297. Tighten
    Tighten the bolts to 13 N·m (9 lb ft).


    Object Number: 909455  Size: SH
  298. Install the parking lock pawl in the transaxle case.

  299. Object Number: 909458  Size: SH
  300. Install the parking lock pawl shaft with the clamp groove (1) upward, then install the pawl shaft clamp and the 2 bolts.
  301. Tighten
    Tighten the bolts to 5.5 N·m (49 lb in).


    Object Number: 909462  Size: SH
  302. Coat the new O-rings with T-IV automatic transmission fluid.
  303. Install the O-rings on the underdrive brake piston.

  304. Object Number: 909476  Size: SH
  305. Place the underdrive brake piston into the case with the cup side up, being careful not to damage the O-rings.

  306. Object Number: 909099  Size: SH
  307. Install the underdrive brake return spring sub-assembly in the transaxle case.

  308. Object Number: 909090  Size: SH

    Important:  Install the flange with the flat side facing downward.

  309. Install the Plates, underdrive clutch Discs and Flange in the following order: P - D - P - D - P - D - F.

  310. Object Number: 908938  Size: SH
  311. Using a press, compress the flange and install the underdrive clutch flange snap ring in the transaxle case.

  312. Object Number: 908931  Size: SH

    Important: While applying compressed air, measure the pack clearance. The pack clearance should be within 1.15-1.97 mm (0.0453-0.0776 in). If the pack clearance is not as specified, check for incorrect assembly.

  313. Using a dial indicator, measure the underdrive brake pack clearance.

  314. Object Number: 909484  Size: SH
  315. Coat the 2 new overdrive clutch drum oil seal rings with T-IV automatic transmission fluid.
  316. Install the seal rings in the transaxle case.

  317. Object Number: 909487  Size: SH
  318. Install the underdrive 1 way clutch assembly and the underdrive clutch drum thrust washer in the transaxle case.

  319. Object Number: 908894  Size: SH
  320. Push the underdrive 1 way clutch retainer in until it clicks into place.
  321. Coat the underdrive clutch drum thrust washer with petroleum jelly, then install the thrust washer on the underdrive 1 way clutch assembly.
  322. Align the flukes of the discs in the underdrive brake.
  323. Install the underdrive clutch drum assembly in the transaxle case.

  324. Object Number: 909490  Size: SH
  325. Turn the underdrive clutch assembly. The clutch assembly should turn freely counterclockwise (1) and should lock clockwise  (2).

  326. Object Number: 909498  Size: SH
  327. Install the assembled bearing and race with the thrust needle roller bearing facing upward

  328. Object Number: 909499  Size: SH
  329. Using Vernier Calipers, check the height from the sleeve to the inner race. The correct installation height should be 17.3-18.2 mm (0.681-0.717 in).

  330. Object Number: 908879  Size: SH
  331. Install a dial indicator on the underdrive clutch piston.

  332. Object Number: 908888  Size: SH

    Important: If the piston stroke is not within 1.5-1.9 mm (0.059-0.075 in). Install a different size flange. There are 4 thicknesses available, 2.04 mm (0.803), 2.20 mm (0.866), 2.40 mm (0.945), 2.50 mm (0.984).

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

  334. Object Number: 909500  Size: SH
  335. Remove the underdrive planetary sun gear from the countershaft assembly.
  336. Remove the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race.

  337. Object Number: 909501  Size: SH
  338. Install the underdrive planetary sun gear sub - assembly in the transaxle case.
  339. Coat the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race with petroleum jelly or equivalent.
  340. Install the bearing and race in the transaxle case.
  341. Align the flukes of the discs in the underdrive clutch.
  342. Install the needle roller bearing with the bearings facing upward.

  343. Object Number: 909503  Size: SH
  344. Install the countershaft assembly in the transaxle case.

  345. Object Number: 909506  Size: SH
  346. Using Vernier Calipers, measure the distance between the tip of the countershaft and the bolt seat of the clutch support. The installation height should be 33.3-35.5 mm (1.311-1.398 in).
  347. Install the new counterdrive gear bearing on the counterdrive gear.
  348. Install a new snap ring to retain the bearing.

  349. Object Number: 927972  Size: SH
  350. Using a press, install the counter drive gear.

  351. Object Number: 927983  Size: SH
  352. Install the intermediate shaft sub-assembly in the transaxle case.

  353. Object Number: 927989  Size: SH
  354. While holding the counter drive gear, install a new counter drive gear nut.
  355. Tighten
    Tighten the nut to 180 N·m (133 lb ft).


    Object Number: 928028  Size: SH

    Important: If the torque exceeds the limit, replace the spacer.

  356. Using a torque wrench, measure the starting torque of the counter drive gear.
  357. Starting Torque
    0.11-0.70 N·m (0.9-6.1 lb in).

    Rotating Torque
    0.04-0.30 N·m (0.3-2.6 lb in).


    Object Number: 928031  Size: SH
  358. Using a pin punch and hammer, stake the counter drive gear nut.

  359. Object Number: 928037  Size: SH
  360. Install the needle roller bearing in the transaxle case.

  361. Object Number: 928050  Size: SH
  362. Using a press, install the counter driven gear on the transaxle case.
  363. Install a new counter driven gear nut.
  364. Tighten
    Tighten the nut to 180 N·m (133 lb ft).


    Object Number: 928186  Size: SH
  365. Using a dial indicator, measure the endplay of the countershaft.
  366. Endplay
    Endplay should be within 0.2-0.9 mm (0.008-0.035 in).


    Object Number: 928188  Size: SH
  367. Using a pin punch and hammer, stake the counter driven gear nut.

  368. Object Number: 928194  Size: SH
  369. Clean the mating surfaces of the transaxle case and the case cover.
  370. Apply RTV Silicone Sealant GM P/N 12346240 (Canadian P/N 10953493) or the equivalent to the transaxle case cover.

  371. Object Number: 928209  Size: SH
  372. Install bolts A: 25 mm (0.98 in) in length into the positions shown.
  373. Install bolts B: 32 mm (1.26 in) in length into the positions shown.
  374. Tighten
    Tighten all 13 bolts to 10 N·m (7 lb ft).


    Object Number: 928217  Size: SH
  375. Ensure that the intermediate shaft sub-assembly turns smoothly.

  376. Object Number: 928222  Size: SH
  377. Coat the 2 new 1st and reverse O-rings with T-IV automatic transmission fluid.
  378. Install the new O-rings on the 1st and reverse brake piston.

  379. Object Number: 928231  Size: SH
  380. Install the 1st and reverse brake piston into the bore of the case, facing the spring seats upward.

  381. Object Number: 928239  Size: SH
  382. Install the 1st and reverse brake return spring and snap ring into position.

  383. Object Number: 928251  Size: SH
  384. Using a press, compress the 1st and reverse brake return spring sub-assembly.
  385. Using snap ring pliers, install the snap ring.

  386. Object Number: 928303  Size: SH
  387. Install the 1st and reverse brake clutch discs, in the following order: P - D - P - D - P - D - P - D - P - D - P - D.

  388. Object Number: 928345  Size: SH
  389. Install the outer flange with the flat side facing downward.

  390. Object Number: 928347  Size: SH

    Important: Ensure that the snap ring end gap is not aligned with one of the cutouts.

  391. Using a screwdriver, install the snap ring to the transaxle case.

  392. Object Number: 928362  Size: SH

    Important: If the clearance is not within specification, parts have been misaligned and should be rechecked for correct installation.

  393. Using a feeler gage, measure the 1st and reverse brake pack clearance. Pack clearance should be 1.19-2.25 mm (0.0469-0.0886 in).

  394. Object Number: 928367  Size: SH
  395. Coat the needle roller bearing with petroleum jelly, then install the bearing on the ring gear.

  396. Object Number: 928369  Size: SH

    Important: Ensure that the different lug shapes match the corresponding openings on the gear.

  397. Coat the planetary gear thrust washer No. 2 with petroleum jelly, then install the thrust washer on the rear planetary gear assembly.

  398. Object Number: 928373  Size: SH
  399. Align the splines of the rear planetary gear assembly with the flukes of the discs, then install the rear planetary gear assembly into the 1st and reverse brake discs.

  400. Object Number: 928377  Size: SH
  401. Check that (1) of the rear planetary gear assembly is below the upper surface of the flange.

  402. Object Number: 928461  Size: SH
  403. Place the 1 way clutch No. 2 in the transaxle case with the shiny side facing upward.
  404. Install the 1 way clutch onto the inner race while turning the rear planetary gear assembly clockwise (2).
  405. Check that the rear planetary gear assembly turns freely clockwise  (2) and locks when turned counterclockwise (1).

  406. Object Number: 928843  Size: SH
  407. Coat the planetary gear thrust washer No.2 with petroleum jelly, then install it on the planetary gear.

  408. Object Number: 928846  Size: SH
  409. Ensure the end gap of the snap ring is not aligned with the cut outs.

  410. Object Number: 928864  Size: SH
  411. Install the 2nd brake clutch flange with the flat side facing upward.

  412. Object Number: 928873  Size: SH
  413. Install the 2nd brake clutch discs and plates, in the following order: D - P - D - P - D - P.

  414. Object Number: 928881  Size: SH
  415. Install each of the 2nd brake piston return spring sub-assembly over the protrusions in the transaxle case.

  416. Object Number: 928883  Size: SH
  417. Install the 2nd coast brake band guide plate retainer and brake band plate retainer so that its tip touches the transaxle case.
  418. Install the retaining bolt.
  419. Tighten
    Tighten the bolt to 5.5 N·m (49 lb in).


    Object Number: 928892  Size: SH
  420. Align the groove of the drum with the bolt and place the 2nd brake piston assembly into the transaxle case.

  421. Object Number: 928894  Size: SH
  422. Place both ends of the snap ring in the groove, then set the snap ring in the transaxle case.
  423. Important: Ensure the end gap of the snap ring is not aligned with one of the cut outs.

  424. While compressing the piston return springs over the drum with hammer handles, install the snap ring.

  425. Object Number: 928902  Size: SH
  426. Using compressed air, check that the 2nd brake piston moves smoothly.

  427. Object Number: 928907  Size: SH
  428. Using a screwdriver, align the flukes of the discs in the 2nd brake.

  429. Object Number: 928913  Size: SH
  430. Align the spline of the 1 way clutch with the flukes of the discs then install the 1 way clutch to the 2nd brake discs.

  431. Object Number: 928917  Size: SH
  432. Check the clearance between the surface of the 2nd brake hub and the rear planetary gear. The clearance should be approximately 5 mm (0.20 in).

  433. Object Number: 928919  Size: SH
  434. Coat the planetary carrier thrust washer No. 3 with petroleum jelly, then install the thrust washer on the sun gear input drum.

  435. Object Number: 928972  Size: SH
  436. Position the sun gear input drum into the 1 way clutch assembly, then turn the sun gear input drum clockwise to seat the assembly in the installed position.

  437. Object Number: 928980  Size: SH
  438. Coat the thrust roller bearing and thrust bearing race with petroleum jelly, then install them on the front planetary gear assembly.

  439. Object Number: 929066  Size: SH
  440. Install the front planetary gear assembly.

  441. Object Number: 929122  Size: SH
  442. Coat the thrust bearing race and thrust roller bearing with petroleum jelly.
  443. Install the thrust bearing race, then the thrust roller bearing on the front planetary ring gear assembly.

  444. Object Number: 929123  Size: SH
  445. Install the front planetary ring gear in the transaxle case.

  446. Object Number: 929124  Size: SH
  447. To ensure the front planetary ring gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with or under the shoulder of the intermediate shaft.

  448. Object Number: 929151  Size: SH
  449. Coat the thrust roller bearing and thrust bearing race with petroleum jelly, then install the bearing and race on the tip of the ring gear flange.

  450. Object Number: 929164  Size: SH
  451. Place the 2nd coast brake band assembly into the transaxle case.
  452. Install the 2nd coast brake band pin in the transaxle case.

  453. Object Number: 929166  Size: SH
  454. Coat the thrust roller bearing with petroleum jelly, then install the bearing on the forward clutch drum.

  455. Object Number: 929168  Size: SH
  456. Coat the clutch drum thrust washer with petroleum jelly, then install the thrust washer on the direct clutch drum with the oil groove facing upward.

  457. Object Number: 929177  Size: SH
  458. Using a screwdriver, align the flukes of the discs in the direct clutch.

  459. Object Number: 929203  Size: SH

    Important: When the flukes of the discs are meshed correctly, the end of the bushing on the direct clutch will be flush with the surfaces of the forward clutch.

  460. Mesh the hub with flukes of the direct clutch while turning the forward clutch drum.

  461. Object Number: 929206  Size: SH
  462. Place the direct clutch assembly and the forward clutch assembly into the transaxle case.
  463. While rotating the forward clutch assembly to mesh the front planetary ring gear and discs, install the assembly in the transaxle case.

  464. Object Number: 929208  Size: SH
  465. Using a feeler gage, check the clearance between points (1) and (2). The clearance should be 3 mm (0.118 in).

  466. Object Number: 929209  Size: SH
  467. Coat the 2 new O-rings with T-IV automatic transmission fluid, then install the O-rings on the 2nd coast brake cover.

  468. Object Number: 929214  Size: SH
  469. Install the spring 2nd coast brake piston assembly and 2nd coast brake cover into the transaxle case.

  470. Object Number: 929245  Size: SH
  471. Using snap ring pliers, install the 2nd coast brake piston snap ring

  472. Object Number: 929255  Size: SH
  473. Inspect the piston stroke of the 2nd coast brake by applying a small amount of paint to the piston rod where it meets the case.

  474. Object Number: 929267  Size: SH

    Important: If the piston stroke exceeds 1.5-3.0 mm (0.059-0.118 in). Install a new piston rod.

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

  476. Object Number: 929269  Size: SH
  477. Using a soft faced hammer, install the governor pressure tube in the transaxle case.

  478. Object Number: 929273  Size: SH
  479. Install the transaxle apply tube clamp and bolt in the transaxle case.
  480. Tighten
    Tighten the bolt to 5.5 N·m (49 lb in).


    Object Number: 930074  Size: SH
  481. Coat a new O-ring with T-IV automatic transmission fluid, then install the O-ring on the oil pump.
  482. Place the oil pump over the input shaft, then align the bolt holes of the pump body with holes in the transaxle case.

  483. Object Number: 930081  Size: SH
  484. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the input shaft through the direct clutch drum.

  485. Object Number: 930087  Size: SH
  486. Install the 6 bolts.
  487. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 930093  Size: SH

    Important: If the end play is not within 0.3-0.9 mm (0.012-0.035 in). Replace the race for the end of the input shaft assembly. There are 3 thicknesses available, 0.8 mm (0.31 in), 1.40 mm (0.055 in), 1.0 mm (0.039 in).

  488. Using a dial indicator, measure the end play of the input shaft.

  489. Object Number: 930097  Size: SH
  490. Ensure that the input shaft rotates smoothly.

  491. Object Number: 930120  Size: SH
  492. Install the governor apply gasket No. 2 in the transaxle case.
  493. Install the transaxle case plate No.1 and bolt in the transaxle case.
  494. Tighten
    Tighten the bolt to 10 N·m (7 lb ft).


    Object Number: 930356  Size: SH
  495. Install the differential assembly into the transaxle case.

  496. Object Number: 930359  Size: SH
  497. Clean the mating surfaces of the transaxle case and the transaxle housing.
  498. Apply RTV Silicone Sealant GM P/N 12346240 (Canadian P/N 10953493) or the equivalent to the transaxle case cover.

  499. Object Number: 930366  Size: SH
  500. Apply Threadlocker 242 GM P/N 12345382 or the equivalent to the threads of bolts (2). These bolts are 35 mm (1.38 in) in length.
  501. Install the (2) bolts.
  502. Tighten
    Tighten the bolts to 28 N·m (20 lb ft).

  503. Install the (1) bolts.
  504. Tighten
    Tighten the bolts to 28 N·m (20 lb ft).


    Object Number: 930367  Size: SH
  505. Using J 35405 and a torque wrench, rotate the differential in both directions to seat the bearing.
  506. Using J 35405 and a torque wrench, measure the preload of the side bearing.
  507. Starting Preload

        • New Bearing: 0.8-1.4 N·m (6.9-12.2 lb in).
        • Used Bearing: 0.04-0.7 N·m (3.5-6.1 lb in).

    Important: The preload will change about 0.3-0.4 N·m (2.6-2.9 lb in) according to a change in shim thickness of 0.05 mm (0.0020 in).

  508. If the preload is not within specification, remove the differential from the transaxle case. Select a new transaxle case side adjusting shim. Refer to General Specifications .

  509. Object Number: 930368  Size: SH
  510. Using a 14 mm (0.55 in) socket and hammer, drive in a new manual valve lever shaft oil seal.
  511. Apply multi-purpose grease to the seal lip.

  512. Object Number: 930369  Size: SH
  513. Install the parking lock rod assembly to the manual valve lever sub-assembly.
  514. Slide in the manual valve lever shaft, then install the washer plate, a new spacer and manual valve lever sub-assembly.

  515. Object Number: 930372  Size: SH

    Important: Ensure there is a washer between the retaining spring and case.

  516. Install the retainer spring.

  517. Object Number: 930478  Size: SH
  518. Using a pin punch and hammer, install the roll pin.
  519. Position the spacer, then stake the spacer.

  520. Object Number: 930484  Size: SH
  521. Coat the new O-rings with T-IV automatic transmission, them install the O-rings on the accumulator pistons.
  522. Important: Springs should be installed in the following order: A - Yellow, B - Yellow, C - Light Blue, D - Purple, E - Pink.

  523. Install the accumulator springs and pistons in the transaxle case.

  524. Object Number: 930794  Size: SH
  525. Install a new brake drum gasket until it makes contact with the 2nd brake drum.

  526. Object Number: 930800  Size: SH
  527. Install the new governor apply gasket No.1 in the transaxle case.

  528. Object Number: 908228  Size: SH
  529. Install the check ball body and spring in the transaxle case.

  530. Object Number: 908226  Size: SH
  531. Coat a new O-ring with T-IV automatic transmission fluid, then install the O-ring on the transmission wire harness connector.
  532. Install the transmission wire into the transaxle case.

  533. Object Number: 908223  Size: SH
  534. Install the connector retaining bolt.
  535. Tighten
    Tighten the bolt to 5.5 N·m (49 lb in).


    Object Number: 930806  Size: SH
  536. Connect the manual valve connecting rod to the manual valve lever.

  537. Object Number: 931020  Size: SH

    Important: The bolt length for: Locations (1) - 20 mm (0.79 in), Locations (2) - 28 mm (1.18 in), Locations  (3) - 50 mm (1.97 in).

  538. Install the valve body with the 17 retaining bolts.

  539. Object Number: 908210  Size: SH
  540. Connect the solenoid connectors.

  541. Object Number: 908207  Size: SH
  542. Install the manual detent spring sub-assembly.
  543. Install the manual detent spring cover and bolt.
  544. Tighten
    Tighten the bolt to 10 N·m (7 lb ft).


    Object Number: 931024  Size: SH

    Important: The bolt length for: Locations (1) - 12 mm (0.47 in), Location  (2) - 20 mm (0.79 in).

  545. Install the valve body oil filter and gasket, then install the 3 bolts
  546. Tighten
    Tighten the bolts to 10 N·m (7 lb ft).


    Object Number: 931032  Size: SH
  547. Install the 2 transaxle oil pan magnets on the oil pan.

  548. Object Number: 931037  Size: SH
  549. Install a new oil pan gasket and oil pan on the transaxle case.
  550. Install the 18 oil pan retaining bolts.
  551. Tighten
    Tighten the bolts to 5.3 N·m (47 lb in).


    Object Number: 908194  Size: SH
  552. Coat 2 new O-rings with T-IV automatic transmission fluid.
  553. Install the O-rings on the 2 oil cooler pipe unions.
  554. Install the unions on the transaxle case.
  555. Tighten
    Tighten the unions to 28 N·m (20 lb ft).


    Object Number: 908190  Size: SH
  556. Install the PNP switch to the manual shift lever
  557. Place a new lock washer and nut on the manual shift lever.
  558. Tighten
    Tighten the nut to 7.0 N·m (62 lb in).

  559. Temporarily install the 2 PNP switch retaining bolts.

  560. Object Number: 931039  Size: SH
  561. Temporarily install the transmission control shift lever.
  562. Turn the lever counterclockwise until it stops, then turn the lever clockwise 2 notches.
  563. Remove the lever from the transaxle case.

  564. Object Number: 931045  Size: SH
  565. Align the groove  (1) with neutral line  (2).
  566. Tighten the 2 bolts.
  567. Tighten
    Tighten the bolts to 5.5 N·m (49 lb in).

  568. Install the transmission control shaft lever with the nut and washer.
  569. Tighten
    Tighten the nut to 12 N·m (8 lb ft).

  570. Install the transaxle case plug No. 1 with a new O-ring on the transaxle case.
  571. Install the breather plug No. 1 with a new O-ring on the transaxle case.
  572. Install the breather hose.