GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - AF23-5 🢒 1-2-Reverse Carrier Gear Assembly Installation

    Object Number: 1463930 Size: SH

    Important: To reduce clutch noise, the 1-2 reverse internal gear (594) design was changed. The change was to the bearing flange thickness on the gear and now shimming is required. When installing the 1st design gear do not use the shim (596). When installing the 2nd design gear the shim (596) is required for proper endplay.

  1. Measure the 1-2 reverse internal gear (594) on the bearing flange surface in order to determine if the gear is the 1st design or the 2nd design.

    2. Specifications

        • 1st design bearing flange thickness 4.40 mm (0.1732 in)
        • 2nd design bearing flange thickness 3.62 mm (0.1425 in)

    Object Number: 749472 Size: SH
  2. Rotate the transmission case assembly so that the torque converter housing side is facing up.
  3. Install the 1-2 reverse internal gear rear thrust bearing assembly (595) with the flat side up.
  4. If using the 2nd design 1-2 reverse internal gear, Install the 1-2 reverse internal gear shim (596) without any markings. Correct shim selection is performed during the front differential transfer drive gear assembly installation.
  5. Install the 1-2 reverse internal gear (594).
  6. Install the 1-2 reverse internal gear front thrust bearing assembly (593) with the flange up.

    7. Object Number: 749470 Size: SH
  7. Install the 1-2 reverse internal gear thrust washer (590) to the lower side of the 1-2 reverse carrier gear assembly (591).
  8. Install the 1-2 reverse carrier gear assembly (591) into the 1-2 reverse internal gear (594). The carrier assembly will be flush to the 1-2 reverse internal gear.
  9. Install the 1-2 reverse carrier thrust washer (590) on top of the 1-2 reverse carrier gear assembly (591).