GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - AF23-5 🢒 Forward and Direct Clutch End Play Measurement

Tools Required

    • J 45166 8" Dial Indicator Extension Rod
    • J 8001 Dial Indicator Set

    Object Number: 749483 Size: SH
  1. Install the transmission case cover assembly (19) to the transmission case assembly (17).

    2. Object Number: 749817 Size: SH
  2. Rotate the transmission case so that the front section of the case is facing up.
  3. Install the 8 mm threaded end of J 45166  (2) into the case bolt hole as indicated in the graphic.
  4. Install J 8001  (1) onto J 45166  (2) as shown and set the dial indicator to zero.

    5. Important: Excessive upward pressure will cause an incorrect reading.

  5. With one hand, carefully pull straight up on the forward and direct clutch assembly (23) input shaft until the assembly first bottoms out.
  6. Record the measurement.

    7. Object Number: 749803 Size: SH
  7. Compare the measurement with the listed specification.

    8. Specification
    Forward and direct clutch assembly end play 0.188-0.570 mm (0.007-0.022 in)

  8. If out of specifications, remove the transmission case cover assembly.
  9. Replace the forward clutch housing selective thrust bearing race (628) as needed to obtain the correct end play specification.

    10. Object Number: 749483 Size: SH
  10. If the end play measurement is within specifications, rotate the transmission case assembly so that the transmission case cover side is facing up.
  11. Remove the transmission case cover assembly (19) and clean the sealing surfaces of the transmission case cover (19) and the transmission case assembly (17).