Part 2
Transmission Overhaul Part 2
Underdrive Brake Assembly Replacement
Removal Procedure
1. Remove the 2 underdrive brake piston seals from the underdrive brake piston.
2. Clean all the underdrive brake components and dry thoroughly.
3. Inspect the underdrive brake discs for excessive wear or damage and replace as necessary.
4. Inspect the underdrive brake piston for cracks or porosity and replace as necessary.
5. Inspect the underdrive brake piston return spring for distortion or weakness and replace as necessary.
Installation Procedure
Install the new underdrive brake piston seals onto the underdrive piston.
Differential Side Bearing Preload Adjustment
Tools Required
* J 35405 Differential Preload Wrench
* J 26941 Countershaft Bearing Drive Axle Seal Remover
* J 2619-01 Slide Hammer
* J 35552 Differential Side Bearing Cup Installer
* J 8092 Driver Handle
Adjustment Procedure
1. Insert the J 35405 into the drive axle shaft bore in the torque converter housing until the J 35405 engages with the pinion shaft (1) of the differential.
2. Rotate the differential several times in both directions in order to ensure that the differential bearings have seated. Measure the differential side bearing preload. Standard differential side bearing preload should fall within the following ranges:
* New differential side bearings 0.8-1.4 N.m (7-12 lb in)
* Reused differential side bearings 0.4-0.7 N.m (4-6 lb in).
Important: Differential side bearing selective shims sizes are available in increments of 0.05 mm (0.002 in). Refer to Differential Side Bearing Selective Shim Sizes Table in Transmission General Specifications (Transmission General Specifications)
3. Differential side bearing preload (differential starting torque) will change approximately 0.3-0.4 N.m (2.5-3.5 lb in) by increasing or decreasing one shim size.
4. If the differential side bearing preload is below specification, increase the size of the left differential side bearing selective shim in the transaxle case. If the differential side bearing preload is above specification, decrease the size of the left differential side bearing selective shim in the transaxle case.
1. Remove the 17 torque converter bolts and the torque converter housing from the transaxle case.
2. Remove the differential assembly from the transaxle case.
3. Use the J 26941 with the J 2619-01 in order to remove the left differential side bearing race and the selective shim.
4. Use the J 35552 with the J 8092 and a hammer in order to install an appropriate size left differential side bearing selective shim and race into the transaxle case.
Refer to Transmission General Specifications (Transmission General Specifications).
Underdrive Brake Assembly Installation
Tools Required
* J 36850 Transjel(R) Lubricant
* J 23327 Clutch Spring Compressor
* J 37282 Piston Brake Compressor
Important: When installing new clutch discs in the 1st-reverse brake, the underdrive brake, the underdrive clutch, the intermediate brake, the forward clutch or the direct clutch assemblies, the new clutch discs MUST be soaked in Dexron(R)-III Automatic Transmission Fluid GM P/N 12346143 or equivalent, two hours prior to installation. This causes the clutch material on the discs to permeate with fluid which will aid in ease of assembly and prevent clutch overheating on first time engagement.
1. Install the 2 new seal rings onto the underdrive clutch drum support (2).
2. Apply J 36850 in order to the two new underdrive clutch drum support seal rings (3).
3. Apply J 36850 in order to the two new underdrive brake piston seals.
4. Install the underdrive brake piston (1) into the transaxle case with the cup side facing upwards.
5. Install the underdrive brake piston return spring (1) into the transaxle case.
6. Install the underdrive brake flange (2), three plates (3) and three discs (1) into the transaxle case in the following order:
1. Plate
2. Disc
3. Plate
4. Disc
5. Plate
6. Disc
7. Flange
7. Align the inner teeth of the underdrive brake discs (2).
8. Install the J 23327 with the J 37282 into the transaxle case and compress the underdrive brake piston return spring until the underdrive brake piston return spring snap ring can be installed.
9. Install the underdrive brake snap ring into the transaxle case.
10. Remove the J 37282 and the J 23327 from the transaxle case.
11. Measure the underdrive brake assembly (1) using a J 7872 . Apply 392-785 kPa (57-114 psi) of compressed air into the underdrive brake apply passage (2).
* Verify that the underdrive brake assembly clearance falls within 1.07-2.05 mm (0.0421-0.0807 in).
* If the underdrive brake assembly clearance does not fall within specification, inspect the underdrive brake assembly for excessive wear.
Underdrive Clutch Assembly Installation
Tools Required
* J 36850 Transjel(R) Lubricant
* J 26900-6 Dial Caliper
1. Inspect the underdrive one-way clutch for correct installation by simultaneously placing the underdrive one-way clutch onto the rear of the underdrive clutch drum (1), holding the underdrive clutch drum stationary and rotating the underdrive one-way clutch (4) by hand.
* The underdrive one-way clutch must turn freely in a counterclockwise direction (2) for correct installation. If the underdrive one-way clutch turns freely in a clockwise direction (3), the underdrive one-way clutch is installed backwards (upside down).
* Remove the underdrive one-way clutch and reinstall correctly.
* Repeat the above inspection to verify correct installation.
2. Install the underdrive one-way clutch (1) into transaxle case.
3. Install the underdrive one-way clutch anti-rattle clip (1) into the transaxle case.
4. Apply J 36850 (3) to the underdrive one-way clutch thrust washer (2) in order to hold it in place on the rear of the underdrive clutch drum (1).
5. Install the underdrive one-way clutch thrust washer in order to hold it in place on the rear of the underdrive clutch drum.
6. Install the underdrive one-way clutch assembly (1) into the underdrive one-way clutch and underdrive brake assembly.
7. Measure the underdrive clutch assembly installation depth using a J 26900-6
* Measure the installation depth from the top of the underdrive clutch drum support (2) to the top of the underdrive clutch drum (1). The underdrive clutch assembly installation depth should fall within 17.3-18.2 mm (0.681-0.717 in).
* If the underdrive clutch assembly installation depth does not fall within specification, remove the underdrive clutch assembly and repeat the underdrive clutch assembly installation procedure until the underdrive clutch assembly installation depth is within specification.
First Reverse Brake Assembly Installation
Important: When installing new clutch discs in the 1st-reverse brake, the underdrive brake, the underdrive clutch, the intermediate brake, the forward clutch or the direct clutch assemblies, the new clutch discs MUST be soaked in Dexron(R)-III Automatic Transmission Fluid GM P/N 12346143 or equivalent, two hours prior to installation. This causes the clutch material on the discs to permeate with fluid which will aid in ease of assembly and prevent clutch overheating on first time engagement.
1. Install the five plates (2) and the five discs (1) in the transaxle case in the following order:
1. Plate
2. Disc
3. Plate
4. Disc
5. Plate
6. Disc
7. Plate
8. Disc
9. Plate
10. Disc
Important: The 1st-reverse brake flange must be installed with the flat side facing down and the stepped portion facing upwards.
2. Install the 1st-reverse brake flange (2).
3. Install the 1st-reverse brake snap ring (1) into the transaxle case (2).
4. Measure the 1st-reverse brake assembly clearance using a feeler gage (2).
* The 1st-reverse brake assembly clearance should fall within 1.06-2.38 mm (0.04170-0.0937 in).
* If the 1st-reverse brake assembly clearance is above 1.06 mm (0.0417 in), inspect the 1st-reverse brake assembly for excessive wear.
Second Coast Brake Installation
Tools Required
* J 36850 Transjel(R) Lubricant
* J 26900-6 Dial Caliper
Notice: If the 2nd coast brake band appears excessively worn or damaged and replacement is necessary, the new brake band should be soaked in Dexron(R)-III Automatic Transmission Fluid GM P/N 12346143, or equivalent, for two hours prior to installation. This causes the band material to permeate with fluid which will prevent the band overheating on first time application.
1. Install the 2nd coast brake band (2) into the transaxle case. Secure the brake band with the 2nd coast brake band anchor pin (1).
2. Apply J 36850 to the outer forward clutch thrust bearing.
3. Install the forward clutch outer thrust bearing (1) over the input shaft and into the forward clutch drum.
Important: During direct clutch thrust washer installation, verify that the oil grooves (brass surface) are facing toward the forward clutch.
4.
Apply J 36850 (1) to the direct clutch thrust washer (2) in order to hold it in place on the direct clutch drum.
5. Install the direct clutch thrust washer onto direct clutch drum.
6. Align the inner teeth of the direct clutch discs (1).
7. Install the direct clutch assembly (1) onto the forward clutch assembly (2) by rotating the direct clutch drum back and forth until the direct clutch inner teeth of the direct clutch discs mesh with the forward clutch drum.
8. Align the inner teeth of the forward clutch discs.
9. Apply J 36850 to the forward clutch inner thrust bearing in order to hold it in place in the center of the forward clutch drum.
10. Install the forward clutch inner thrust bearing into the center of the forward clutch drum.
11. Install the forward and direct clutch assemblies (2) onto the front planetary ring gear by rotating the input shaft (1) back and forth until the inner teeth of the forward clutch discs mesh with the front planetary ring gear.
12. Measure the installation depth of the forward and the direct clutch assemblies by measuring the gap between the direct clutch drum (1) and the sun gear input drum using a J 26900-6
13. Verify that the gap between the direct clutch drum and the sun gear input drum (2) is approximately 3 mm (0.118 in) (3).
14. If the gap between the direct clutch drum and the sun gear input drum is greater than specification, remove the forward and direct clutch assemblies and reinstall until the distance is within specification.
15. Apply J 36850 to the 2nd coast brake servo piston and cover seals.
16. Install the 2nd coast brake outer return spring (4), the 2nd coast brake piston (1) and the 2nd coast brake servo cover (3) into the transaxle case.
17. Install the 2nd coast brake servo cover snap ring (2) into the transaxle case.
18. Measure the 2nd coast brake servo piston stroke.
* Place a reference mark on the 2nd coast brake piston rod where the piston rod meets the transaxle case.
* Apply 392-785 kPa (57-114 psi) of compressed air into the 2nd coast brake apply passage.
* Measure the distance between the reference mark and the transaxle case using a feeler gage to obtain the 2nd coast brake piston stroke.
* Verify that the 2nd coast brake piston stroke falls within 1.5-3.5 mm (0.059-0.138 in).
* If the 2nd coast brake piston stroke does not fall within specification, inspect the 2nd coast brake band for excessive wear or damage.
19. Install the 2nd coast brake apply pipe (2) into the transaxle case.
Notice: Refer to Fastener Notice
20. Install the 2nd coast brake apply pipe bracket (2) into the transaxle case. Secure the pipe bracket with one bolt.
Tighten the 2nd coast brake apply pipe bracket bolt to 5 N.m (44 lb in).