GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 VUE - AWD 🢒 Transmission/Transaxle 🢒 Automatic Transmission - 5AT 🢒 Output Shaft Assemble

Tools Required

    • DT 46509 Tube Style Driver
    • SA9179NE Dial Indicator

    Object Number: 1344624 Size: SH
  1. Install the following components on the output shaft:
    2. • The 1st/2nd driven gear (523)
    • The 1st/2nd driven gear 65 x 83 x 4.5 mm thrust bearing (522)
    • The 1st/2nd idler gear 57 x 65 x 28.7 mm inner bearing (521)
    • The 1st/2nd idler gear (520) with shoulder side down
    • The 1st/2nd idler gear 56 x 878.5 x 5.5 mm thrust bearing (519)
    • The 1st driven gear 56 mm selective spacer (518)

    Object Number: 1203927 Size: SH
  2. Put a straight edge across the top of the 1st/2nd idler gear thrust bearing (519).
  3. Using a feeler gage measure between the straight edge and the roller bearings on the 1st/2nd idler gear thrust bearing (519) in 3 places. Use the average of the 3 measurements as the actual clearance.
  4. Measure the 1st/2nd idler gear (520) axial clearance in at least 3 places on the gear. Use the average of the 3 measurements as the actual clearance.

    5. Specification
    1st/2nd idler gear clearance 0.005-0.040 mm (0.0002-0.0016 in)

  5. If the measurement exceeds the specifications, remove and measure the thickness of the 1st driven gear 56 mm selective spacer (518).
  6. Select and install a new 1st driven gear 56 mm selective spacer (518) in order to obtain the specified clearance. Measure the clearance again to ensure that the 1st/2nd idler gear is within specifications.

    7. Object Number: 1203924 Size: SH
  7. Install the following components on the output shaft:
    8. • The 1st driven gear (517) with the gear protrusion facing up
    • The 3rd/4th driven gear (500) with the gear protrusion facing up
    • The 3rd/4th driven gear 50.2 mm selective spacer (501)
    • The 3rd/4th driven gear 39 mm split retaining rings (502)
    • The 3rd/4th driven gear 39 mm retaining ring cap (503)
    • The 3rd/4th driven gear 39 mm retaining ring cap retainer (504)

    Object Number: 1203928 Size: SH
  8. Measure the clearance between the 3rd/4th driven gear (500) and the 3rd/4th driven gear 50.2 mm selective spacer (501) with a feeler gage (1) in at least 3 places. Use the average of the 3 measurements as the actual clearance.

    9. Specification
    The clearance between the 3rd/4th driven gear and the 3rd/4th driven gear selective spacer 0.005-0.040 mm (0.0002-0.0016 in).

  9. If the measurement exceeds 0.040 mm (0.016 in), remove and measure the thickness of the 3rd/4th driven gear 52 mm selective spacer (501).
  10. Select and install a new 3rd/4th driven gear 52 mm selective spacer (501) in order to obtain the specified clearance, then check for the proper clearance again.

    11. Object Number: 1203930 Size: SH
  11. Install the following components on the output shaft:
    12. • The 5th driven gear spacer (505)
    • The 5th driven gear inner bearing (506)
    • The 5th driven gear (507)
    • The 5th/reverse synchronizer hub (509)

    Object Number: 1203931 Size: SH
  12. Using a hydraulic press and DT 46509 complete the installation of the 5th/reverse synchronizer hub (509).

    13. Object Number: 1507158 Size: SH
  13. Measure the 5th driven gear (507) axial clearance.
    14. 13.1. Install SA9179NE on the 5th driven gear.
    13.2. Zero the gage.
    13.3. Lift up on the 5th driven gear and record the measurement.

    Specification
    5th driven gear axial clearance 0.12-0.27 mm (0.0047-0.0106 in)

    13.4. If the clearance exceeds specifications inspect for excessive wear on the thrust surface of the 5th driven gear (507), the 5th/reverse synchronizer hub (509), and the shoulder of the output shaft (524).
    13.5. If there is not any clearance, ensure the 5th/reverse synchronizer hub (509) is completely installed and there are no burrs or debris between the gears.

    Object Number: 1344625 Size: SH
  14. Install the following components on the output shaft (524):
    15. • The 5th/reverse synchronizer sleeve (508)
    • The reverse driven gear 31 x 40 x 14.5 mm inner bearing race (510)
    • The reverse driven gear 40 x 46 x 14.5 mm inner bearing (511)
    • The reverse driven gear (512)

    Object Number: 1203933 Size: SH
  15. Using the DT 46509 and a hydraulic press, install the output shaft 31 x 93 x 19 mm rear bearing (514) on the output shaft (524).

    16. Object Number: 1507159 Size: SH
  16. Measure the reverse driven gear (512) axial clearance.
    17. 16.1. Install SA9179NE on the reverse driven gear.
    16.2. Zero the gage.
    16.3. Lift up on the reverse driven gear and record the measurement.

    Specification
    Reverse driven gear axial clearance 0.10-0.25 mm (0.0039-0.0098 in)

    16.4. If the clearance exceeds specifications inspect for excessive wear on the thrust surface of the reverse driven gear (512) or the 5th/reverse synchronizer hub (509).
    16.5. If there is not any clearance, ensure the output shaft rear bearing (514) is completely installed and there are no burrs or debris between the gears.

    Object Number: 1203934 Size: SH
  17. Install an output shaft washer (515) in the direction as shown.
  18. Loosely install an output shaft retaining nut (516).

    19. Object Number: 1203935 Size: SH

    Important: 

       • Do not use an impact wrench to tighten the nut.
       • The nut is left handed thread.

  19. To tighten the retaining nut (516), use an adjustable wrench mounted in a vise. Securely hold the output shaft in the adjustable wrench while tightening.

    20. Tighten
    Tighten the nut to 167 N·m (123 lb ft).


    Object Number: 1203936 Size: SH
  20. Using a 3.5 mm (9/64 in) punch (b), stake the output shaft nut (516) in place on the output shaft (524) to the specified depth (a).

    21. Specification
    Stake the nut to 0.7-1.3 mm (0.03-0.05 in.)