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Saturn Transmission. Manual - part 20

DOWEL

BOLT

DOWEL

BOLT

Figure 187

Figure 188

Figure 186

INSTALL RETAINING BOLT

24. Torque all 14 bolts to 11. N m (97 in. lbs.) in the
numerical sequence shown in Figure 188.

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TRANSAXLE ASSEMBLY

1. Install a new pump to case O ring on the pump

assembly and secure with petroleum jelly (See
Figure 189).
2. Install the stator shaft caged needle bearing into
the pump housing and lubricate with transmission
fluid (Figure 189).
3. Attach the parking pawl assembly to the case and
tighten the three bolts to 30 N m (22 Ft. lbs).
4. Install the park lever actuator rod. The end with
the two tangs fit into the lever.
5. Install the input shaft, output shaft and differential.
Grasp the input shaft and output shaft and mesh
the gears. Have an assistant mesh the differential
ring gear to the output shaft. Lower all three
components at the same time. Apply petroleum
jelly on the output shaft bearing to aid in the
installation (See Figure 190).
NOTICE: Input shaft, output shaft and
differential must be installed at the same time
or damage may occur to the output shaft roller
bearing inner race. Bearing failure will result.

6. Install a new linkage seal and lubricate with

petroleum jelly (See Figure 191).
7. Install the input and output shaft case bearings into
the case. Using a suitable pair of snap ring pliers,
expand the snap ring and slide the bearing into the
bearing bores. Snap ring grooves on the bearing
should be UP on the output shaft bearing and
DOWN on the input shaft bearing (See Figure
192).
8. Install a new O ring onto one end of the reverse
idler gear shaft. Lube and install the reverse idler
gear bearing and install a new O ring onto the
opposite end of the shaft (See Figure 193).

Figure 189

Figure 190

Figure 191

Figure 192

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Figure 193

Figure 194

Figure 195

9. Install the reverse idler gear with the chamfer
side of the gear towards the rear of the case
(See Figure 193).
10. Lube the O rings and install the shaft through the
rear of the case. Use a twisting motion and make
sure the O rings stay in position (See Figure 193).
11. Install the reverse idler shaft cap using a twisting
motion and torque the two bolts to 15 Foot lbs.
(See Figure 193).
IMPORTANT: If the transaxle was built in
early 1991 production year, the reverse idler
gear shaft will not be equipped with O rings. If
the transaxle is being overhauled, the shaft and
idler gear should be updated.

12. Install case to rear cover dowel pins if necessary.

13. Clean case and housing surfaces and apply sealant
Loctite 515 or equivalent. Apply to both sides of
the gasket or case halves using a small roller (See
Figure 194).
14. Lower the case over the shafts and work down
onto the differential bearing. It may be necessary
to turn the reverse idler gear to index the gears
allowing the case to drop down into place (See
Figure 194).
15. Install the case to converter housing bolts. Torque
the bolts to the following specifications and in the
numerical sequence shown in Figure 195.
A) Short Bolts.....25 N m (18 ft. lbs.)
B) Long Bolts.....28 N m (21 ft. lbs.)
IMPORTANT: The two bolts on the torque
converter side of the housing should not be
installed at this time.

Chamfer

side of gear

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16. To check the differential end play, remove the
selective snap ring from the differential bearing
bore as shown in Figure 196.
17. With a feeler gauge, measure the clearance from
the bearing to the top of the snap ring groove (See
Figure 197).
18. The snap ring to be used should measure the same
in thickness as to the amount of clearance that was
measured in step 17. The ball bearings on the
differential should have 0 clearance with no
preload when the snap ring is installed. Below is
the list of the different selective snap rings with
their sizes and part numbers.

19. Apply sealant Loctite 515 or equivalent to area of
axle seal and install new axle seals (See Figure
198).
20. Install a new forward/reverse servo piston sealing
ring as shown in Figure 199.
A) Place servo piston on the seal installer base
(SA9137T-2)
B) Install the seal expander cone (SA9137T-1) to
the servo piston.
C) Lube sealing ring and position on expander
cone.
D) Use the seal pusher (SA9143T) to install the
sealing ring.

Figure 196

Figure 197

Figure 198

Figure 199

21002329
21002324
21002325
21002326
21002327
21002328
21002330
21002331

1.30mm
1.40mm
1.50mm
1.60mm
1.70mm
1.80mm
1.90mm
2.00mm

0.051 in.
0.055 in.
0.059 in
0.063 in.
0.067 in.
0.071 in.
0.075 in.
0.079 in.

1)
2)
3)
4)
5)
6)
7)
8)

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