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Transaxle Reassembly

NOTE: Apply manual transaxle fluid (Saab 400108247 or Saturn 21018899) to all rotating parts and bearings during reassembly.
  1. Install differential into clutch case. Ensure oil guide is installed into clutch case prior to installing output shaft. Install output shaft into clutch housing bore. Using a plastic hammer, start bearing race into clutch case bore. Install bearing support and tap down bearing race using Output Shaft Bearing Race Sleeve (87-92-202) and Handle (87-91-204). Apply Loctite to all bearing support screws. Install 3 middle screws and tighten alternately to specification, then install and tighten outermost screw to specification. See TORQUE SPECIFICATIONS  .
    2. NOTE: There must be a clearance of .591" (15 mm) between 1st driven gear and clutch case to install input shaft.
  2. Install 1st and 2nd driven gears, held together with Assembly Fixture (87-92-103), onto output shaft with their appropriate synchronizer assembly. Install 3rd driven gear and spacing sleeve onto output shaft. Install input shaft assembly into clutch case. Secure input and output shafts together using plastic retaining strap.
  3. Ensure gear teeth are properly meshed. Using Output Shaft Bearing Race Sleeve (87-91-204) and Input Shaft Bearing Ring (87-90-867), carefully tap gears onto output shaft until gears are against surface of clutch housing. Install NEW crush sleeve. Install 4th driven gear with machined groove facing toward 3rd gear. Using Output Shaft Remover/Installer (87-91-261), press down until 4th driven gear is even with 4th gear. Remove plastic retaining strap(s) and assembly fixture. Lift input shaft slightly and install reverse gear assembly. See Fig 1 . Ensure hole in reverse gear shaft is facing channel in clutch case.
  4. Place 1st/2nd synchronizer sleeve on output shaft in 2nd gear position. Place 3rd/4th synchronizer sleeve on input shaft in 4th gear position. Insert 1st/2nd and 3rd/4th shift forks into synchronizer sleeves and push gear change mechanism into place. Install locating sleeves and loosely install outboard gear change mechanism bolt. See Figure .
  5. Install reverse shift lever assembly, with oil plate under edge of gear change mechanism. Loosely install long reverse shift lever assembly bolt. Apply thread sealant to short reverse shift lever assembly bolt. Install short reverse shift lever assembly bolt. Tighten all gear change mechanism and reverse shift lever assembly bolts to specification. See TORQUE SPECIFICATIONS  .
  6. Install reverse gear fork onto reverse gear synchronizer sleeve. Ensure reverse gear lever is in groove of reverse gear fork. Install reverse gear fork shaft. Engage reverse gear using shift linkage assembly and check for full engagement of Reverse. Lightly lubricate shift shaft with grease and insert through seal in clutch case. Insert shift shaft through shift shaft block. See Figure . Place shift shaft block into position and install shift shaft bolt. Tighten shift shaft bolt to specification.
  7. Using shift control shaft, shift transaxle to all gear positions to check operation. Check shift interlocking feature by trying to engage 1st and Reverse gears at same time. It should not be possible to engage 1st and Reverse gears at same time if shift interlocking feature is working properly. Apply Loctite 518 to contact surfaces of transaxle case and clutch case. Ensure filter vent is not blocked. Ensure reverse gear shaft is correctly positioned so bolt with "O" ring can be installed after gear case installation.
  8. Install transaxle case onto clutch case, and start 2 transaxle case-to-clutch case bolts by hand. Tap up alignment sleeves and loosely install reverse gear shaft support bolt with "O" ring. Install remaining transaxle case-to-clutch case bolts. Tighten transaxle case-to-clutch case bolts to specification in a crisscross pattern. See TORQUE SPECIFICATIONS  . Tighten reverse gear shaft support bolt.
  9. Lubricate output shaft bearing. Using Output Shaft Remover/Installer (87-91-261), pull output shaft bearing onto output shaft until it just touches retaining sleeve. Install 5th driven gear onto output shaft. Tap 5th driven gear down with Inner Drive Sleeve (78-41-067) to allow for installation of output shaft remover/installer. Install output shaft remover/installer and pull 5th driven gear down until it is against output shaft bearing. Install NEW output shaft nut, but DO NOT tighten at this time.
  10. Using plastic hammer, carefully tap input shaft from engine side so input shaft bearing race is against input shaft bearing retainer. Install a drill with Input/Output Shaft Driver (87-91-428) to input shaft. Install dial indicator with tip placed on input shaft bearing inner race. See Fig 2 . Spin transaxle about 20 revolutions while pushing and pulling on drill to seat bearings. Zero gauge on dial indicator. Spin transaxle about 20 revolutions while pushing and pulling on drill to measure input shaft axial play. Input shaft axial play should be .004-.006" (.09-.15 mm). If input shaft axial play is as specified, go to step  12 . If input shaft axial play is not as specified, go to next step.
  11. Add or replace input shaft bearing retainer shims as necessary to adjust input shaft axial play to specification. Add shims to decrease preload and remove shims to increase preload. Shims are available in .004" (.10 mm), .006" (.15 mm) and .012" (.30 mm) thicknesses.
  12. Tighten input shaft bearing retainer bolts to specification. See TORQUE SPECIFICATIONS  . Lubricate and install 5th gear needle bearing, 5th gear and 5th gear synchronizer blocking ring. Install Pulling Eyes (87-92-129) onto transaxle case. Ensure wire coil on synchronizer blocking ring is fitted and set 5th gear synchronizer hub into place on input shaft. Set Bearing Driver Shaft Sleeve (87-91-311) onto 5th gear synchronizer hub. Install Puller (87-91-287) with Short Arms (87-91-303) into pulling eyes. Carefully install 5th gear synchronizer hub with 3 notches over heels of synchronizer blocking ring. Ensure flat side of sleeve faces upward and bosses on sleeve fit into deep notches of synchronizer hub. Remove puller, short arms and pulling eyes.
  13. Align tall teeth on 5th gear synchronizer sleeve with deep grooves on synchronizer hub and install while referencing alignment mark made during disassembly. Install an M8 bolt to transaxle case near 5th driven gear. See Fig 3 . Install dial indicator on top of 5th driven gear. Engage 1st gear. Engage 5th gear by pressing down on 5th gear synchronizer sleeve. Zero dial indicator. Slide screwdriver under 5th driven gear as far as possible, using M8 bolt as a fulcrum point. Measure output shaft end play while prying up on 5th driven gear. Output shaft end play should be 0-.004" (0-.11 mm). Tighten output shaft nut until end play is within specification.
  14. Disengage 1st gear and remove 5th gear synchronizer sleeve. Install Milled Bearing Race (87-92-137) in place of left differential bearing race. Install shims equal to about .08" (2 mm) on top of milled bearing race. Remove "O" ring from axle seal retainer. Set axle seal retainer onto transaxle case, but do not install retaining bolts. Place 22 lb. (10 kg) weight on axle seal retainer. See Fig 4 . Install Companion Flange (87-92-053) onto output shaft. Using a drill and companion flange, spin differential clockwise about 20 revolutions.
  15. Measure clearance between axle seal retainer and transaxle case with feeler gauge in 3 places. Take average value of readings and select appropriate .004" (.10 mm), .006" (.15 mm), .012" (.30 mm) or .020" (.50 mm) shim(s) to adjust differential end play to specification. See DIFFERENTIAL END PLAY SPECIFICATIONS  table.
    DIFFERENTIAL END PLAY SPECIFICATIONS

    Application In. (mm)
    Used Transaxle Case & Used Bearing, Over 31,500 Miles (50,000 km) .008 (.20)
    Used Transaxle Case & New Bearing, Over 31,500 Miles (50,000 km) .012 (.30)
    New Transaxle Case & New Bearing .014 (.35)
  16. Remove weight from axle seal retainer. Remove axle seal retainer. Remove milled bearing race. Install NEW differential bearing race. Tap differential bearing race down using Sleeve (83-90-114). Install appropriate shim(s) determined by differential end play measurement. Lubricate and install NEW "O" ring onto axle seal retainer. Set axle seal retainer onto transaxle case. Install axle seal retainer bolts by hand. Tighten axle seal retainer bolts only far enough to obtain a clearance of .006" (.15 mm) between axle seal retainer and transaxle case.
  17. Place transaxle assembly in a horizontal (in-car) position. Ensure transaxle is in Neutral. Remove hose from Input/Output Shaft Driver (87-91-428). Install a 3/8" drive 16 mm deep well socket into one end of hose removed from input/output shaft driver. Place other end of hose over input shaft (engine side) of transaxle. See Fig 5 . Connect an INCH-lb torque wrench to 16 mm socket.
  18. Rotate transaxle input shaft several times at an even speed with torque wrench. Read average value on torque wrench while rotating transaxle input shaft. Average required torque should be 1-3 INCH-lbs. (.10-.30 N.m). If average required torque is as specified, go to next step. If average required torque is not as specified or varies greatly while rotating input shaft, transaxle should be disassembled and inspected for possible bearing contamination or other problem.
  19. Place transaxle assembly in a vertical position. Install dial indicator on top of 5th driven gear. See Fig 6 . Install Companion Flange (87-92-053) onto output shaft. Using a drill and companion flange, spin output shaft clockwise several times to seat bearings. Press down on drill and spin output shaft clockwise for about 20 revolutions. Zero dial indicator. Pull up on drill and spin output shaft clockwise about 20 revolutions, observing measurement when dial indicator reading stabilizes. Take average value of reading and add this to appropriate value depending on clutch case/output shaft bearing being used. See OUTPUT SHAFT END PLAY SPECIFICATIONS  table. This is the measurement the output shaft nut will need to be turned.
    OUTPUT SHAFT END PLAY SPECIFICATIONS

    Application In. (mm)
    Used Clutch Case & Used Output Shaft Bearing, Over 31,500 Miles (50,000 km) .000 (.00)
    Used Clutch Case & Used Output Shaft Bearing, Under 31,500 Miles (50,000 km) .001 (.03)
    Used Clutch Case & New Output Shaft Bearing .003 (.08)
    New Clutch Case & New Output Shaft Bearing .006 (.15)
  20. Remove drill, companion flange and dial indicator. Engage 1st gear. Engage 5th gear by pressing down on 5th gear synchronizer sleeve. Install Output Shaft Nut Socket (87-92-061) onto output shaft nut. Set output shaft nut socket to measurement determined earlier. Mark tooth on 5th driven gear that aligns with correct number on output shaft nut socket. See Fig 7 . Tighten output shaft nut in 3 stages until "0" on output shaft nut socket is aligned with marked tooth on 5th driven gear.
  21. Place transaxle assembly in a horizontal (in-car) position. Disengage transaxle from 1st gear and remove 5th gear synchronizer sleeve. Ensure transaxle is in Neutral. Install torque wrench on output shaft nut. Spin output shaft clockwise at an even speed while observing average reading on torque wrench. Subtract average required torque measurement while rotating transaxle input shaft taken in step  18 from average required torque measurement while rotating transaxle output shaft. This is calculated output shaft turning torque, normally 4.5-9.0 INCH lbs. (.5-1.0 N.m).
  22. If average torque is 4.5-9.0 INCH lbs. (.5-1.0 N.m), go to next step. If average torque is less than 4.5 INCH lbs. (.5 N.m), bearings are not sufficiently tight. Tighten output shaft nut by 2 increments on output shaft nut socket. Take another measurement and repeat procedure until correct torque is reached. If average torque more than 9.0 INCH lbs. (1.0 N.m), bearings are contaminated or too tight. Install a NEW crush sleeve and reset bearing preloads. If average torque varies greatly, bearings are contaminated or synchronizer blocking rings are faulty. Disassemble transaxle, inspect components and repair/replace as necessary.
  23. Lock output shaft nut using hammer and chisel. Place transaxle assembly in a vertical position. Engage 3rd gear. Install 5th gear fork and synchronizer sleeve together, referencing sleeve alignment mark made during disassembly and aligning tall teeth on sleeve with deep grooves on hub. Install NEW 5th gear synchronizer hub snap ring. Install NEW 5th gear fork retaining pin. See Figure . Tighten axle seal retainer bolts to specification. See TORQUE SPECIFICATIONS  .
  24. Clean and dry rear cover gasket surfaces. Install rear cover with NEW gasket. Install rear cover mounting bolts and tighten to specification in a crisscross pattern. Install back-up light switch with NEW gasket and tighten to specification. Ensure magnet exists in transaxle drain plug. Clean transaxle drain plug and apply thread sealant to threads. Install transaxle drain plug and tighten to specification. Apply grease (Saturn 21005995 or equivalent) between lips of input shaft seal. Apply Loctite 592 to slave cylinder bolts. Install slave cylinder. Install slave cylinder bolts and tighten to specification. Install fluid supply line and sleeve to slave cylinder.
Fig 1: Installing Reverse Gear Assembly
G95E20762Courtesy of SAAB-SCANIA OF AMERICA, INC.
Fig 2: Measuring Input Shaft Axial Play
G00025526Courtesy of GENERAL MOTORS CORP.
Fig 3: Measuring Output Shaft End Play
G95F20763Courtesy of SAAB-SCANIA OF AMERICA, INC.
Fig 4: Measuring Differential Bearing Support End Play
G95J20767Courtesy of SAAB-SCANIA OF AMERICA, INC.
Fig 5: Measuring Required Torque To Spin Transaxle
G00025527Courtesy of GENERAL MOTORS CORP.
Fig 6: Setting Output Shaft Bearings
G95G20764Courtesy of SAAB-SCANIA OF AMERICA, INC.
Fig 7: Tightening Output Shaft Nut
G00025528Courtesy of GENERAL MOTORS CORP.
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