Input Internal Gear, Carrier, Sun Gear Assemble. Chevrolet Beretta 1996

For 1990-2009 cars

1. Inspect the input carrier assembly (640) for the following conditions:

• | Pinion damage

• | Carrier wear

• | Spline damage

2. Inspect the input thrust washers (639, 641) for wear. Inspect the washers for bent or damaged tangs.
3. Use a feeler gage in order to measure the pinion end play. End play should measure 0.24-0.69 mm (0.009-0.027 in).

Important: If the pinion end play is outside of these dimensions, replace the input carrier (640).

4. Inspect the input shaft thrust washer (636) for damage.
5. Inspect the input internal gear (637) for the following conditions:

• | Damaged splines

• | Blocked or missing lube holes

• | Damaged gear teeth

• | Worn bushing

6. Inspect the input sun gear (642) for the following conditions:

• | Worn gear teeth

• | Damaged splines

• | A worn thrust surface

Important: Before installing the sun gear, confirm that the machined grooved side is facing down.

7. Insert the input sun gear (642) into the case.
8. Use TRANSJEL™ or equivalent in order to affix the two thrust washers (639, 641) onto the input carrier assembly (640).
9. Install the input carrier (640) into the case. Use a slight twisting motion in order to engage the pinions into the sun gear.
10. Install the input internal gear (637) into the case. Use a slight twisting motion in order to engage the input carrier pinions.
11. Insert the thrust washer (636) for the input shaft into the case.