Saturn Transmission. Manual - part 12

     9. Remove the 3rd driven gear split washers and the
         3rd/4th gear double sided needle bearing (See
         Figure 92).
  10.  Lift off the 4th driven gear, the 4th driven gear
         caged bearing, the 4th driven gear double sided
         needle bearing washer and the solid toothed
         thrust washer. Inspect all parts for wear and
         replace if necessary (See Figure 92).
   11. Remove the 4th clutch housing and O rings from
         the output shaft (See Figure 93).

 NOTE: It may

         be necessary to use a press to remove the 4th
         clutch housing. 

FIRST CLUTCH DRUM DISASSEMBLY
     

1. Remove the 1st drive gear from the 1st clutch

         drum assembly and inspect the teeth and bearing
         race for wear, chipping or pitting and replace as
         necessary (See Figure 94).
     2. Remove the caged needle bearing from the 1st
         clutch drum assembly by carefully expanding the
         caged bearing from the open end separating it
         from the inner race (See Figure 94).
     3. Remove the single sided bearing thrust washer
         (See Figure 94).
     4. Remove the tanged bearing race washer (See
         Figure 94). Inspect all bearings and races for wear.
     5. Remove the backing plate snap ring, the backing
         plate, the single sided clutch plates and clutch
         apply plate (See Figure 95).
         NOTE: 1992 and up 1st clutch drum uses a
         beveled spring and external tang clutch plate in
         place of the clutch apply plate.   
     

6. Install Saturn's spring return compression fixture

         (SA9146T) or equivalent and compress the spring.
         Use snap ring pliers to remove the retaining snap
         ring. Slowly release the spring tension and remove
         the fixture and spring assembly  (See Figure 96).  

Figure 93

Figure 95

Figure 94

Figure 96

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     7. Carefully apply approximately 5 psi of air pressure
         to the clutch housing feed orifice and blow the
         piston out of its bore or gently tap the drum on the
         bench until the piston comes out of its bore (See
         Figure 97). 
         NOTE: Inspect the inner and outer lip seal area
         of the molded piston for hardened, cracked or
         worn out areas. Replace the piston if any of these
         conditions exist.

SECOND CLUTCH DRUM DISASSEMBLY
     

1. Remove the backing plate snap ring, the backing

         plate, the single sided clutch plates and clutch
         apply plate (See Figure 98).
     2. Install Saturn's spring return compression fixture
         (SA9146T) or equivalent and compress the spring.
         Use snap ring pliers to remove the retaining snap
         ring. Slowly release the spring tension and remove
         the fixture and spring assembly  (See Figure 99).
     3. Carefully apply approximately 5 psi of air pressure
         to the clutch housing feed orifice and blow the
         piston out of its bore or gently tap the drum on the
         bench until the piston comes out of its bore (See
         Figure 100).   
         NOTE: Inspect the inner and outer lip seal area
         of the molded piston for hardened, cracked or
         worn out areas. Replace the piston if any of these
         conditions exist.

THIRD CLUTCH DRUM DISASSEMBLY
    

 1. Flip the 2/3 clutch drum housing over and remove

         the backing plate snap ring, the backing plate, the
         single sided clutch plates and clutch apply plate
         (See Figure 101).

Figure 97

Figure 98

Figure 99

Figure 100

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     2. Install Saturn's spring return compression fixture
         (SA9146T) or equivalent and compress the spring.
         Use snap ring pliers to remove the retaining snap
         ring. Slowly release the spring tension and remove
         the fixture and spring assembly  (See Figure 102).
     3. Carefully apply approximately 5 psi of air pressure
         to the clutch housing feed orifice and blow the
         piston out of its bore or gently tap the drum on the
         bench until the piston comes out of its bore (See
         Figure 103).           
         NOTE: Inspect the inner and outer lip seal area
         of the molded piston for hardened, cracked or
         worn out areas. Replace the piston if any of these
         conditions exist.

Figure 101

Figure 102

Figure 103

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Figure 104

FOURTH CLUTCH DRUM DISASSEMBLY
     1. Remove the backing plate snap ring, the backing
         plate, the single sided clutch plates and clutch
         apply plate (See Figure 104).
     2. Install Saturn's spring return compression fixture
         (SA9146T) or equivalent and compress the spring.
         Use snap ring pliers to remove the retaining snap
         ring. Slowly release the spring tension and remove
         the fixture and spring assembly  (See Figure 105).
     3. Carefully apply approximately 5 psi of air pressure
         to the clutch housing feed orifice and blow the
         piston out of its bore or gently tap the drum on the
         bench until the piston comes out of its bore.
       

  NOTE: Inspect the inner and outer lip seal area

         of the molded piston for hardened, cracked or
         worn out areas. Replace the piston if any of these
         conditions exist.

ALL CLUTCH PISTON INSTALLATION
     

1. After all pistons and drums have been thoroughly

         inspected for damage or wear and corrective
         measures where taken, clean all clutch housings
         and pistons.
    

 2. All clutch pistons are to be installed with Saturn's

         4 piece seal protector installation kit SA9117T4 or
         equivalent (See Figure 106).
         A) SA9117T-1 is a driver used to push the piston
               into the drum. It aligns itself to the inner seal
               protector.
         B) SA9117T-2 is a first stage inner seal protector
              for the 2nd, 3rd and 4th clutch drums.
         C) SA9117T-3 is the second stage inner seal
              protector for the 2nd, 3rd and 4th clutch drums.
              It also is the only inner seal protector to be used
              on the 1st clutch drum assembly.
         D) SA9117T- 4 is the outside seal protector for all
              4 pistons. One side is used for the 1st clutch
              piston while the other side is for the 2nd, 3rd
              and 4th clutch pistons. 
     3. To install the 1st clutch drum piston, place the
         SA9117T-3 tool onto the center hub of the 1st
         clutch drum as shown in figure 107.
     4. Lube the clutch piston seals with petroleum jelly
         and place the 1st clutch piston into the SA9117T-4
         tool. Lay the piston and tool onto the 1st clutch
         drum and carefully push the piston down into the
         drum using the SA9117T-1 aligning tool (See
         Figure 108).
     5. Install the 2nd, 3rd and 4th clutch piston as 
         previously explained. The only difference is both
         the SA9117T-2 and 3 inner seal tool are used
         together because the inside diameter of these
         pistons is larger than the 1st clutch drum and
         piston.

Figure 105

SA9117T-1

SA9117T-4

SA9117T-3

SA9117T-2

Figure 106

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