Saturn Transmission. Manual - part 11

       simultaneously and lift the internal filter and the
       entire pump assembly off the case (See Figure 75).
 26. Inspect the output shaft bearing. If damaged,
       remove and replace the bearing using Saturn's tool
       SA9113T and SA9113T or equivalent as shown in
       Figure 76.
 27. Flip the converter housing over and remove the
       front seal retaining snap ring with a suitable pair of
       snap ring pliers (See Figure 77).
 28. Using a seal puller or a long screw driver, carefully
       remove the front seal without damaging the case
       (See Figure 77).
 29. To inspect the converter bearing for damage,
       remove the bearing retaining ring with the same
       pair of snap ring pliers (See Figure 77).  
 30. Using the same puller tool described in step 26,
       remove the converter bearing from the case as
       shown in Figure 78.
 31. Remove the axle seal as shown in figure 79 in the
       converter housing using Saturn's tool SA9133T or
       equivalent using the following procedure:

       a) Carefully remove the seal dust cover by tapping
           a screwdriver into the side of the cover and pry
           outward.
       b)  Remove the seal by threading the puller through
            the steel part of the seal body as close to the
            outside diameter as possible without damaging
            the seal bore in the case (See Figure 79).

 32. Place the converter housing case aside and repeat
       the same procedure to remove the axle seal in the
       main case.
 33. Remove the two 10mm reverse idler gear cap 

Figure 78

Figure 79

INSERT SEAL PULLER

HERE TO REMOVE SEAL

Figure 80

       retaining bolts and lift the cap from the case (See
       Figure 80).
 34. Once the cap is removed, reach inside the case to
       hold the reverse idler gear while pulling out the
       reverse idler gear shaft (See Figure 80).
       NOTE: The shaft contains two O rings which may
       cause difficulty in removing the shaft. Rotating the
       shaft while pulling will aid in its removal.
       SEE SPECIAL NOTE ON PAGE 85 STEP 11.
 

35. Once the shaft has cleared the case, the reverse 

       idler gear and bearing can be removed from the
       case (See Figure 80).
 36. It is advised to remove the rear cover dowel pins as
       a safety precaution to prevent any possible damage
       to the dowel pins during the case cleaning and
       rebuilding process (See Figure 80).

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Figure 82

Figure 81

 37. To remove the input and output shaft case bearings
       from the transaxle case, use a suitable pair of snap
       ring pliers to EXPAND the ring far enough to slide
       the bearing out of its bore by hand (See Figure 81).
       Caution: Do not over expand the ring causing the
       ring to bend and preventing it from recovering to
       its original tension.  
 38. Remove the linkage seal (See Figure 82).
 39. There is a lube relief valve located in the case along
       side the threaded shaft that the external filter screws
       onto. It is a plastic spring loaded valve that allows
       the flow of oil in one direction only. This valve can
       be checked for damage by viewing the valve to
       determine if it is stuck off of its seat or melted. Also
       check the spring tension by pushing in on the valve.

Figure 83

Figure 84

Figure 85

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Figure 86

Figure 87

Figure 88

       If the valve needs to be replaced, it may become
       necessary to remove the threaded shaft or turn the
       shaft so that the corner of the nut part of the shaft
       does not overlap the valve (See Figure 83).
 40. Remove the valve by using Saturn's extracting tool
       SA9103E or equivalent as shown in Figure 84.
 41. Install a new valve (Part # 25014006) with an 
       appropriate size installation tool (See Figure 85). 

INPUT SHAFT DISASSEMBLY
   1. Remove and inspect the 2nd/reverse single sided
       needle bearing thrust washer (See Figure 86).
   2. Remove the 2nd/reverse gear and inspect the teeth
       and needle bearing races for wear, chipping or
       pitting and replace if necessary (See Figure 86).
   3. Remove and inspect the 2nd/reverse needle bearing
       cage from inside the gear (See Figure 86).
   4. Remove and inspect the 2nd/reverse double sided
       needle bearing thrust washer (See Figure 86).
   5. Remove and discard the three sealing rings on the
       opposite side of the shaft (See Figure 86).
   6. Support the 2nd/3rd clutch drum housing on a press
       with the threaded side of the shaft facing up. Be sure
       that the press is on the drum and not the gear. While
       holding the bottom end of the shaft, press the shaft
       off the 2nd/reverse needle bearing race, thrust
       washer and drum (See Figure 87).
   7. Remove 3 O rings from the input shaft and slide the
       2/3 clutch housing thrust washer off the input shaft
       as well as the double sided needle bearing washer,
       the 3rd drive gear, the 3rd drive gear caged needle
       bearing and the 3rd to reverse gear double sided
       needle bearing. Inspect all bearing races and gear
       teeth for  wear, chipping or pitting and replace if 
       necessary (See Figure 88).
    

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Figure 92

Figure 90

Figure 91

Figure 89

OUTPUT SHAFT DISASSEMBLY
     1. Remove and inspect the reverse driven gear thrust
         washer for wear or scoring and replace if
         necessary (See Figure 89).
     2. Remove the reverse driven gear and inspect the
         teeth and needle bearing race for wear, chipping or
         pitting and replace if necessary (See Figure 89).
     3. Remove the caged needle bearing and inner race
         and check both items for wear (See Figure 89).
     4. Remove the reverse dog clutch sleeve and hub.
         Inspect the sleeve for rounded or worn ends at the
         beginning of the teeth and replace if necessary.
         Also inspect the hub slots for wear.
     5. It may be necessary to utilize a press to remove the
         2nd/reverse driven thrust washer and inner bearing
         race. Place a press support under the 2nd/reverse 
         driven thrust washer as seen in figure 90. Carefully
         press the washer off the shaft while holding the 
         drum assembly and shaft from dropping to the 
         floor. As the shaft is being pressed, the  thrust
         washer will push off the 2nd/reverse driven gear,
         the caged needle bearing and inner race as seen in
         figure 91.
     6. With the 2nd/reverse gear removed, inspect the
         teeth and inner race for wear, chipping or pitting
         and replace if necessary (See Figure 91). NOTE:
         1992 and up models eliminated the caged needle
         bearing and closed the diameter of the gear.
     

7. Remove the 2nd/3rd driven gear spacer collar (See

         Figure 92).
     8. Remove the 3rd driven gear. It may be necessary
         to use a gear puller. Inspect the teeth and bearing
         race for wear, chipping or pitting (See Figure 92).
     

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