Saturn Transmission. Manual - part 17

Figure 157

DIFFERENTIAL DISASSEMBLY
1. Using a suitable drift pin, drive the roll pin from
the differential housing and remove the pinion
shaft and side gears (See Figure 157).
2. Rotate the pinion gears and remove them from the
housing (See Figure 157).
3. Remove the plastic side gear liner from the
housing (See Figure 159).
4. Inspect the pinion shaft for wear, the side gears for
wear and the side gear liner for wear. Replace
if necessary.
5. Inspect the differential side bearings for wear and
pit marks and replace if necessary. To remove the
bearings, use a suitable puller (See Figure 158).
A) To remove the speed sensor side bearing, a
typical puller can be used.
B) To remove the differential gear side bearing,
use a two jaw puller. Place a shield over the
bearing to provide protection if the bearing
should break.

DIFFERENTIAL ASSEMBLY
1. NOTICE: The bearing on the right side (The
vehicle speed sensor side) of the differential has
a black colored cage. (Service bearings
however, will all have a black cage and are
interchangeable).

2. Press the new differential bearings onto the

differential housing using Saturn's tool SA9120T
or equivalent. Check to be sure that the bearings
are fully seated.
3. Install the side gear liner into the housing. Position
the liner inside the housing so that the side gear
section with the alignment tabs set into the pocket
on the ring gear side of the case.

Figure 158

SIDE GEAR

LINER

4. Place the side gears into position in the housing
and hold in position.
5. Install one of the pinion gears on the tabbed side
of the thrust liner and then pull the thrust liner
partially over the pinion gear to hold it into place.
6. Place the second pinion gear into position, directly
opposite from the first pinion gear. Rotate the
thrust liner until the pinion gear holes line up with
the shaft holes in the housing.
7. Install the side gears into the housing.
8. Install the pinion shaft and a new roll pin. Be sure
to drive the roll pin flush to the housing
preventing any interference with the speed sensor
signal.
9. Install the differential assembly into the converter
housing case half.

Figure 159

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 160

Figure 161

1 2

Saturn Tool Set SA9136T

SA9136T-1 Teflon Ring Expander
SA9136T-2 Sizer
SA9136T-3 Short Base
SA9136T-4 Long Base

Figure 162

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

END COVER DISASSEMBLY
1. Using a pair of suitable snap ring pliers, remove
the 4th clutch feed pipe lip seal retainer snap ring
and remove the lip seal (See Figure 160).
2. Remove the 4th clutch feed pipe snap ring retainer
and pull the hub and tube out of the cover (See
Figure 160).
3. Using an 8mm socket, remove the two lube, 1st,
2nd and 3rdclutch retaining bolts from the cover
(See Figure 160).
4. Separate the 4th clutch feed pipe from the flange
(See Figure 161).
5. Remove all O rings and sealing rings and inspect
the tubes and hubs for wear or damage and replace
if necessary.

END COVER ASSEMBLY
1. Using Saturn's seal installation tool or equivalent
(See Figure 162), install new sealing rings onto
the 1st clutch flange (See Figure 163).
2. Place the hub with retaining bolt threads facing
up on the TALL support tool SA9136T-4 (See
Figure 163)
3. Place Sizer SA9136T-2 over the hub, with the
large internal diameter down, to act as a seal stop
(See Figure 163).
4. Install the expander cone SA9136T-1 on the hub
and place the sealing ring onto the cone (See
Figure 163).
5. Use the pusher SA9143T to install the ring (See
Figure 163).

1. Lube, 1st, 3rd and 2nd Clutch Feed
Gasket
2. 2nd Clutch O ring
3. 1st and 2nd Flange
4. 3rd Clutch Feed Pipe
5. 4th Clutch Feed Pipe Hub and O ring
6. Retaining Snap Ring
7. 4th Clutch Feed Pipe
8. Lip Seal Retainer

Figure 163

CORRECT

INCORRECT

SEAL

NOTCH

Figure 164

IMPORTANT: During the 1991 model year, the
hub and seals were revised with a new wider seal
design. In 1991, transaxles with a change code of
0, 1, 2 or 3 may require the hub to be replaced
when replacing the seals (Refer to page 6 for
reading the transaxle build date code).

Figure 164 shows how a seal may be rolled. The
rings must be replaced if this condition exists.

6. Once the ring has been installed, size the sealing
ring by placing the sizer over the hub, with the
large internal diameter down, until it bottoms out
on the work table (See Figure 165).
7. Place the hub with the threads facing down on the
SMALL support SA9136T-3 (See Figure 166).
8. Place sizer over hub, with the large internal
diameter facing down, to act as a seal stop (See
Figure 166).
9. Install the expander cone onto the hub and place
the sealing ring on the expander (See Figure 166).
10. Use the pusher to install the sealing ring (See
Figure 166).

Figure 165

Figure 166

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 168

Figure 169

Figure 170

Figure 167

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

11. Remove the expander cone from the hub and lift
the hub off of the support. Remove the sizer from
the support as well. Place the hub with the threads
facing down on the SHORT support (See Figure
167).
12. Size the sealing ring by placing the sizer over the
hub with the large internal diameter down. Push
carefully over the ring until the sizer bottoms out
on the work table (See Figure 167).
13. Install the roll pin in the 3rd clutch feed pipe and
slide the spacer over the tube and up against the
roll pin. (See Figure 168).
14. Carefully slide a new O ring onto the tube and
push it down against the spacer (See Figure 168).
15. Slide the tube through the 1st, 2nd and 3rd clutch
flange and seat the roll pin into the slots provided
(See Figure 168).
16. Install the roll pin in the 4th clutch feed pipe and
slide the spacer over the tube and up against the
roll pin (See Figure 169).
17. Carefully slide a new O ring onto the tube and
push it down against the spacer (See Figure 169).
18. Slide the tube through the 4th clutch flange and
seat the roll pin into the slots provided (See Figure
169).
19. Place a new O ring around the outside of the 4th
clutch flange (See Figure 169).
20. Install a new gasket into the rear cover for the
lube, 1st and 2nd clutch flange as shown in Figure
170.
21. Install the flange into the rear cover over the
gasket and install and tighten the two retaining
bolts to 12 N m (106 in. lbs). Make sure to line up
the roll pin with the slots in the cover (See Figure
170).

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