Saturn Transmission. Manual - part 16

27. Using a feeler gauge, measure the clearance
between the 4th driven gear and the 3/4 thrust
bearing (See Figure 141). The clearance should be:
0.002 mm - 0.464 mm or
0.00008 in. - 0.018 in.
28. Measure the clearance between the 2nd driven gear
and the dog clutch hub. Move the dog clutch
sleeve as necessary to gain access for
measurements (See Figure 142).
0.050 mm - 0.150 mm or
0.002 in. - 0.006 in.
29. Measure clearance between the reverse driven gear
and the reverse driven gear thrust washer (See
Figure 143).
0.066 mm - 0.172 mm or
0.003 in. - 0.007 in.
30. Measure clearance between the 1st driven gear and
1st driven gear thrust washer (See Figure 144).
0.100 mm - 0.400 mm or
0.004 in. - 0.016 in.
IMPORTANT: There are no selective washers to
adjust end play. If the clearance is not within
specifications, there is either a misassembly
problem or worn parts.

31. Remove the 1st driven gear and sprag clutch

assembly from the output shaft.
32. Remove the output shaft case bearing from the
output shaft.
33. Set aside the 1st driven gear assembly, the output
shaft case bearing and output shaft assembly for
later transaxle reassembly.

Figure 141

Figure 142

Figure 143

Figure 144

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 145

Figure 146

Figure 147

PUMP INSPECTION AND RECONDITIONING
1. Remove the wear plate and pump gears from the
pump housing and inspect the housing, gears and
plate for wear. Replace worn or damaged parts
(See Figure 145).
2. Install the pump driven gear (outer gear) into the
pump housing with the chamfered side down. The
chamfer is located around the outside diameter of
the gear.
3. Install the pump drive gear into the pump housing.
4. Place a straight edge across the pump face and
measure both the drive gear face to straight edge
clearance and the driven gear face to straight edge
clearance (See Figure 146).
Drive Gear Clearance:
0.012 mm - 0.041 mm or
0.0004 in. - 0.0016 in.
Driven Gear Clearance:
0.012 mm - 0.041 mm or
0.0004 in. - 0.0016 in.

5. Measure the driven gear to pump housing
clearance as shown in Figure 147.
Clearance:
0.064 mm - 0.139 mm or
0.0025 in. - 0.0055 in.

6. Measure the clearance between the driven gear and
the crescent in the pump housing as shown in
Figure 148.
Clearance:
0.191 mm - 0.341 mm or
0.0075 in. - 0.0134 in.

DRIVEN GEAR

CRESCENT

Figure 148

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 149

Figure 150

7. Measure the clearance between the drive gear and
the crescent in the pump housing as shown in
Figure 149.
Clearance:
0.128 mm - 0.278 mm or
0.0050 in. - 0.0109 in.

8. Inspect the dowel pins for wear and ensure that
they are pressed down into the housing (See
Figure 150).
9. Clean and install the lube relief valve, spring and
retainer as shown in Figure 150.
10. Clean and install the pump wear plate.
11. Before the pump assembly can be attached to the
converter housing case half, inspect all passages in
the converter housing and ensure that they are
clear and clean.
12. Press converter bearing into the housing using
Saturn's tool SA9114T or equivalent and install
the bearing retaining snap ring (See Figure 151).
13. Install a new torque converter seal using Saturn's
tool SA9107T or equivalent and the seal retaining
snap ring (See Figure 151).
14. If a new output shaft roller bearing is being
installed, install Saturn's press fixture SA9129T
and pad SA1991T-1 or equivalent. The tool is
designed to support the case and prevent case
damage as the new bearing is being installed (See
Figure 152).

DRIVE GEAR

Snap Ring

Converter Seal

Snap Ring

Converter Bearing

Figure 151

Figure 152

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

15. With the press fixture tool installed on the front of
the converter housing, flip the case half over and
press in the output shaft roller bearing using
Saturn's bearing installer SA9114T or equivalent
(See Figure 153).
NOTE: The bearing must be flush or below the
converter housing surface. Use a straight edge
and feeler gauge to make sure that the bearing is
not cocked in the bore. Check the bearing race at
four 90° points. All points must be within
0.04mm (0.0016 in.) of each other.

16. If installing a new internal filter, transfer the

magnet and retaining spring from the old filter.
Remove the old seal from the pump housing and
install a new seal and filter (See Figure 154).
17. Install the pump and filter assembly. Make sure all
components are clean. Use care not to allow the
pump drive gear to catch or scratch the converter
housing surface (See Figure 154).
18. Use Figure 155 to place the bolts in their correct
location. There are seven 8 mm head bolts that
measure 6 mm x 22 mm and five 8 mm head bolts
that measure 6 mm x 45 mm (See Figure 155).
19. Torque each of the pump housing to case bolts to
12 N m (106 inch lbs) in the numerical sequence
shown in Figure 156.
20. If it was necessary to remove the three 13 mm
stator support retaining bolts, torque them down to
30 N m (22 foot lbs) (See Figure 156)
21. Remove the output shaft roller bearing fixture tool.

Figure 154

Figure 155

6 mm x 45 mm

6 mm x 22 mm

Figure 156

Figure 153

22 foot

lbs

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

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