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Transaxle Reassembly

NOTE: Lubricate components during reassembly process with ATF.
  1. Install magnet into clutch housing. Install differential assembly into bottom case half. Install reverse idler gear shaft roll pin into reverse idler gear shaft. Install shaft into transaxle case. Install reverse idler gear onto reverse idler gear shaft.
  2. Install reverse shift lever assembly. See Fig 1 and Fig 4 . Apply thread lock sealant and tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  3. Install 1-2 and 3-4 shift forks on their respective synchronizer sleeves. Install 5th-reverse actuator rod into slot of reverse shift lever. Align shift fork shaft hole in shift forks and with 5th-reverse actuator. Install shift fork shaft through forks with shaft retaining ring groove up.
    4. NOTE: Ensure 5th-reverse actuator and shift forks are aligned properly to expose retaining clip grooves. Attempting to install prior to alignment will bend retaining clip, requiring replacement.
    Fig 1: Installing Reverse Idler Gear Assembly
    G92J14075Courtesy of GENERAL MOTORS CORP.
    Fig 2: Installing Oil Flow Tube
    G92A14076Courtesy of GENERAL MOTORS CORP.
  4. With actuator rod still in reverse shift lever, hold 5th-reverse actuator in position to expose snap ring groove on each end of actuator. Install shift rail actuator retainer clip. Install oil flow tube in pocket of transaxle case, next to reverse shift lever. See Fig 2 .
  5. Apply a bead of Loctite 515 sealant, .04-.12" (1-3 mm) wide, down center of mating surface on bottom case half. Sealant must go completely around 5 bolt holes near differential assembly.
  6. Spread input and output shaft bearing snap rings to allow snap rings to slide over bearings. Seat top case half and install bolts. Tighten bolts in sequence to specification. See Fig 3 . Ensure both shafts rotate freely during tightening process.
    Fig 3: Transaxle Case Bolt Tightening Sequence
    G92B14077Courtesy of GENERAL MOTORS CORP.
  7. With old nut installed on input shaft, use screwdriver to pry shaft upward to seat snap rings. Remove nut and repeat process on output shaft. Measure differential end play between side bearing and case using Differential End Play Tool (SA9112T). Install appropriate differential shim to set end play to zero. Use snap ring of same size and install into housing on top of differential ball bearing. Ensure snap ring sets in groove.
  8. Apply Loctite 515 sealant to top case half axle seal bore and drive in NEW axle seal. Install snap ring. Move 2 shift forks to lock transaxle in 2 gears at the same time.
  9. Press 5th driven gear onto output shaft by placing gear on output shaft, and engage splines. Thread the 5th Driven Gear Installer (SA9211T-1) onto output shaft until snug. Tighten nut on installation tool until 5th driven gear is seated. Remove old output shaft nut, install NEW nut and tighten to specification. See TORQUE SPECIFICATIONS  .
  10. Install 5th gear thrust washer and bearing race, if not already installed. Install 5th drive gear bearing and 5th drive gear. Install 5th gear synchronizer ring to 5th gear. Install 5th gear synchronizer spring to synchronizer.
  11. Install 5th-reverse synchronizer hub to input shaft. Ensure hub and sleeve alignment marks are up. See Figure . If hub is press-fit to input shaft, position hub on shaft and engage splines. Thread the 5th driven gear installer onto input shaft until snug. Tighten nut on installation tool until 5th-reverse hub is seated.
  12. Slide 5th-reverse fork onto synchronizer sleeve and install sleeve onto hub and install fork onto shift fork shaft at same time (ensure tangs on ring are aligned with slots on hub). Install NEW retaining clip. Install 5th-reverse gear synchronizer assembly. Install reverse brake cone and thrust washer. Remove old shaft nut and install NEW input shaft nut. Tighten to specifications.
  13. Unlock shafts by lining up shift forks to neutral gate. Turn reverse brake cone so slots align cone to rear cover. Install shift control housing gasket on case. Install shift housing assembly (ensure it is completely seated on case). Install and tighten retaining bolts after they have been cleaned and lubricated.
  14. Ensure all gears can be selected. Install rear cover gasket. Clean, lubricate and install cover bolts. Tighten to specifications. Install vehicle speed sensor. Install and torque filler plug. Apply light coat of Loctite 515 to area of axle seal that presses into housing. Install right (clutch housing side) axle seal.
  15. Install clutch fork stabilizer and ball stud in clutch housing with hole for ball stud to lower left of output shaft. Torque ball stud. Install clutch fork retainer to clutch fork. Lubricate only fork pivot, and install fork and bearing assembly. Snap fork retainer over ball stud. Place light film of high-temperature grease on input shaft spline.
Fig 4: Exploded View Of Bottom Case Components
G92C14078Courtesy of GENERAL MOTORS CORP.
Fig 5: Exploded View Of Top Case Components
G99E54282Courtesy of GENERAL MOTORS CORP.
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