Saturn Transmission. Manual - part 21

 

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Saturn Transmission. Manual - part 21

 

 

   24. Clean the threads on the fork attaching bolt and 
         apply Loctite  242 Threadlocker or equivalent onto
         the bolt threads.
   25. Install the fork to servo piston bolt and torque to 
         10 N  m (89 in. lbs) as shown in Figure 201.
         IMPORTANT: The bolt to be used must have a  
         long shoulder to properly secure the fork to the
         piston.

Figure 200

   21. Once the sealing ring has been installed, the 
         sealing ring will need to be resized (See Figure
         200).
         A) Place the servo piston onto the seal sizer
              support base (SA9137T-4).
         B) Size the sealing ring by placing the sizer 
              (SA9137T-3) over the piston with the large
              internal diameter down. Carefully work the 
              sizer over the ring until the sizer bottoms out on
              the work table. 
   22. Slide the forward/reverse fork onto the 
         second/reverse sleeve in the gear box (See Figure
         201).
   23. Install the forward/reverse servo piston into the 
         bore and line up the the fork and servo shaft as the
         servo is being pushed into the bore. Before
         pushing the servo in all the way, align the bolt hole
         in the servo to the hole in the fork. The flat on the
         servo shaft should face the valve body opening in 
         the case. This will ensure that the shoulder side of 
         the threaded hole in the shaft is facing the fork for 
         proper bolt installation.
         IMPORTANT: When installing the servo piston
         into the case bore, use care not to roll or cut the
         seal. If the servo piston is being replaced, be 
         sure the proper design is being used as the two
         designs are NOT interchangeable (See Figure
         202).
  

 

   

R

.

Figure 201

FIRST DESIGN            SECOND DESIGN

Figure 202

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   26. Install the servo spring on top of the servo piston
         (See Figure 203).
         IMPORTANT: There are two design servo 
         springs as shown in Figure 204. If spring 
         replacement becomes necessary, be sure that the
         proper design is being used as the two are NOT
         interchangeable.

  

 27. Install a new O ring onto the servo cover (See

         Figure 203).
   28. Install the cover. Be careful not to cut the O ring
         in the servo bore (See Figure 203).
   29. Draw the servo cover down to the case using the
         servo cover retaining bolts and torque the bolts to
         20 N  m (15 ft. lbs).
   30. Install the 1st driven gear and sprag assembly (See
         Figure 205).
   31. Install the 1st driven gear thrust washer (See
         Figure 205).
   32. Move the parking pawl actuator rod to engage the
         parking pawl.
   33. Hand start the output shaft nut and run down with
         a torque wrench (See Figure 205).
         NOTICE: Use a new nut. The torque retention 
         of the old nut is insufficient. Clean shaft threads
         with a wire brush. When tightening and 
         torquing this nut it must be done quickly. The 
         thread locking material used on the new nut 
         will cure in a short time and an incorrect torque
         will occur.

   

34. Torque nut down to 150 N  m (111ft. lbs).

   35. Install the 1st drive gear inner splined thrust
         washer onto the main shaft (See Figure 206).

Figure 204

Appr

oximately

52mm - 2.05 in.

Appr

oximately

62mm - 2.45 in.

FIRST DESIGN            SECOND DESIGN

Figure 203

Figure 205

Figure 206

.

.

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   36. Install the 1st clutch drum and 1st drive gear
         assembly (See Figure 206). Hold the first gear and
         clutch drum assembly and install it onto the main
         shaft. If the assembly is not held together, the
         thrust washer under the 1st drive gear may move
         out of position causing the transmission to bind up
         in reverse.
   37. Install the main shaft holding tool fixture 
         SA9119T or equivalent (See Figure 207).
   38. Hand start the main shaft nut. Run the nut down
         with a torque wrench.
         NOTICE: Use a new nut. The torque retention 
         of the old nut is insufficient. Clean shaft threads
         with a wire brush. When tightening and
         torquing this nut it must be done quickly. The 
         thread locking material used on the new nut 
         will cure in a short time and an incorrect torque
         will occur.

   

39. Torque the nut down to 150 N m (111ft. lbs).

          IMPORTANT: To verify that the 1st clutch 
          clutch drum assembly has been properly
          installed, remove the holding fixture tool and
          check the clearance between the 1st drive gear
          and bearing. 
          
       

   The clearance should be: 

       

   0.075mm - 0.425mm    or     0.003 in. - 0.017 in. 

   40. After the input shaft and output shaft nuts have 
         been installed, verify the transaxle for proper
         operation.

         Disengage the parking pawl.

Figure 207

.

.

       Rotate the input shaft by turning the 1st clutch
       housing. The clutch housing should turn freely in 
       both directions.
       a. If input shaft turns freely in one direction only,
           the 1st clutch is binding.
       b. If input shaft will not turn freely in either
           direction, 2nd, 3rd or 4th clutch is binding.

   41. Install a new end cover gasket (See Figure 208).
   42. Install the end cover by inserting the tubes into the
         end of the shaft. If cover does not seat, turn the 
         shafts to help align the tubes with the bushings in 
         the shafts (See Figure 208).
   43. Install the end cover bolts and torque bolts in the 
         numerical  sequence shown in Figure 209. The 
         bolts should be torqued to 28 N  m (21ft. lbs).

.

.

Figure 208

Figure 209

1

6

10

4

12

8

2

5

9

3

7

11

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AIR PRESSURE TEST PORTS

1ST DESIGN CASE

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