For 1990-2009 cars

#### Tools Required

• | SA9112T Differential End Play Gage

• | SA9133T Axle Seal Installer Driver Handle Included

• | SA9119T Input Shaft Holding Tool

• | SA9137T Servo Piston Seal Installer/Sizer

• | SA9143T Input Shaft Seal Installer

• | SA9163T Converter Endplay Tool

1. Install the case to the converter housing gasket.

Important: Clean the case and housing surfaces, use sealant Loctite 515® Saturn P/N 21005993 or equivalent. Apply onto both sides of the gasket or the case halves using a small roller.

2. Check to make sure the oil pump O-ring, reverse drive gear thrust washer, reverse driven gear thrust washer and park lever rod are in position before installing the case.
3. Install the transaxle case, lower case over the shafts and work down onto the differential bearing. It may be necessary to turn the reverse idler gear so case can fit all the way down on the converter housing.

Important: Clean and lubricate fasteners with Saturn transaxle fluid. Wipe off excess fluid.

Important: Two bolts are on the torque converter side of the housing. Do not turn transaxle over until 1st gears are installed.

4. Install the case to converter housing bolts using torque sequence

Tighten

• | Tighten the case-to-converter housing short bolts to 25 N·m (18 lb ft).

• | Tighten the case-to-converter housing long bolts to 28 N·m (21 lb ft).

5. Check to make sure both shafts rotate freely.
6. Measure differential end play by using SA9112T . Select the largest gage tool that will fit between the case bearing pocket and the outer differential race.
7. Use the part number on the tool to choose and install the correct snap ring.

Important: Prior to using SA9113T , inspect the tool for any nicks or burrs that could damage the seal lip.

8. Apply Loctite 515® Gasket Eliminator sealant Saturn P/N 21005993 or equivalent to area of the axle seal that mates to case and install the case side axle seal using tool SA9113T .
9. Install the axle seal retainer snap ring.
10. Install forward/reverse servo piston seal, if necessary.

Important: Prior to using the SA9143T and SA9137T , inspect the tool for any nicks or burrs that could damage the forward/reverse servo piston seal.

10.1. | Place the servo piston on the seal installer backup base SA9137T-2 (3).

10.2. | Install the expander SA9137T-1 (2) to the servo piston.

10.3. | Lube the seal ring and the position on the expander cone.

| Important: Lube the seal with Saturn transaxle fluid before installation.

10.4. | Use the SA9143T (1) to install the seal.

10.5. | Place the servo piston on the seal sizer holding base SA9137T-4 (2).

10.6. | Size the seal by placing the sizing ring SA9137T-3 (1) over the piston, with the large internal diameter down, until it bottoms out on the work table.

11. Slide the fwd/reverse fork onto the second reverse sleeve.

Important: When installing the servo piston, lube the seal and use care not to roll or cut the seal while inserting into the bore. If the servo piston is being replaced, be sure the current part is used.

12. Insert the fwd/reverse servo piston into the bore and line up the fork and the servo shaft as the servo is pushed in. Before pushing the servo all the way in, align the counter bore bolt hole in the servo with the hole in the fork. The flat on the servo shaft should face the valvebody opening in the case.
13. Clean the bolt threads and apply Loctite 242® Threadlocker Saturn P/N 21485277 or equivalent on the bolt threads.
14. Install the fork to the servo piston bolt and tighten.

Tighten
Tighten the forward/reverse shift fork-to-forward/reverse servo piston bolt to 10 N·m (15 lb ft).

15. Install the servo spring.

Important: Clean and lubricate the fasteners with Saturn Transaxle Fluid. Wipe off excess fluid. Do not use the fasteners to pull the cover down.

16. Install the servo cover O-ring seal to the cover and install the cover. Tighten the two bolts.

Tighten
Tighten the forward/reverse servo piston cover-to-case bolts to 20 N·m (15 lb ft).

17. Install 1st driven gear and sprag assembly.
18. Install 1st driven gear thrust washer.
19. Move the park pawl actuator rod to engage the parking pawl.

Notice: Use a new nut due to insufficient tightening retention of the old nut. Clean the shaft threads with a wire brush. When tightening this nut it must be done with a hand wrench or a torque wrench. Using a power tool will generate excess heat in the fastener causing an incorrect tighten.

20. Hand start the output shaft clamp nut. Run down with a torque wrench.

Tighten
Tighten the output shaft clamp nut to 150 N·m (111 lb ft).

21. Lay the 1st clutch housing on a flat surface.

Notice: Make sure the tabs on 1st gear thrust washer line up with slots on the 1st clutch housing assembly hub or damage to the 1st gear thrust washer will occur.

Important: Chamfer side goes toward the clutch housing and flat side goes toward 1st gear.

22. Apply a generous amount of petroleum jelly to hold the 1st gear thrust washer in place and install the 1st gear thrust washer on the 1st clutch housing assembly hub.
23. Install thrust bearing with rollers down toward the 1st gear thrust washer.
24. Install the 1st clutch, clutch needle bearing.
25. Install the 1st drive gear and hub assembly into the 1st clutch housing assembly by twisting the gear to align the gear hub with the clutch tangs.
26. When installing the 1st drive gear and hub assembly into the clutch pack, rotate the gear and hub assembly back and forth to align the clutch plates. If you are not sure that all of the clutch plates have been engaged, lift the gear out of the clutch housing and verify that all clutch tangs are aligned.
27. Install the 1st gear thrust washer.

Notice: If the assembly is not held together, the gear hub may slide out of the clutch housing which may allow the 1st gear thrust washer to move out of location or allow the clutch plates to be pinched when the input shat nut is tightened.

28. Hold the 1st gear and clutch assembly together and install on the input shaft.
29. Install 1st gear and hub assembly, and 1st clutch housing assembly on the input shaft.
30. Install the input shaft holding tool SA9119T.

Notice: Use a new nut due to insufficient tightening retention of the old nut. Clean the shaft threads with a wire brush. When tightening this nut it must be done with a hand wrench or a torque wrench. Using a power tool will generate excess heat in the fastener causing an incorrect tighten.

31. Hand start the input shaft clamp nut. Run the nut down with a torque wrench.

Tighten
Tighten the input shaft clamp nut to 150 N·m (111 lb ft).

Important: After the input and output shaft nut have been installed, verify proper operation.

Important: To verify the 1st clutch assembly, gear and hub are positioned properly, check clearance between 1st drive gear and bearing.

31.1. | Engage the park pawl.

Clearance
Standard 0.075-0.425 mm (0.003-0.017 in)

31.2. | Rotate the input shaft by turning the 1st clutch housing. The clutch housing should turn freely in both directions.

• | If the input shaft turns freely in one direction only, the 1st clutch is binding.

• | If the input shaft will not turn freely in either direction, 2nd, 3rd, or 4th clutch is binding.

32. Connect the manual valve link to the manual detent lever.
33. Insert the manual detent and link into the transaxle, and connect the park lever actuator rod to the detent lever.
34. Hold the detent lever in position and slide the manual detent lever shaft through the case and detent lever.
35. Line up the flats on the manual detent lever with the flats on the manual detent shaft and install the attachment nut.

Tighten
Tighten the manual detent lever-to-manual detent shaft nut to 12 N·m (9 lb ft).

36. Install the transaxle range switch and retaining bolts; do not tighten at this point.
37. Install the output shaft hub O-ring seal (13) on the output shaft hub (12).
38. Install the input tube seal ring (10) and the inner tube O-ring seal (11).
39. Install the output shaft hub (12) on the output shaft tube (9) and align the roll pin in the notch in the hub.
40. Lube the output shaft hub O-ring seal (13) and install the input shaft tube assembly in the end cover aligning the roll pin in the end cover.
41. Install the output shaft hub retaining ring (14).
42. Install the output shaft lip seal (15) and the output shaft lip seal retainer ring (16). Ensure the lip seal does not bind during installation.
43. Install the 2 input shaft hub ring seals (7) on the input shaft pilot hub (6).
44. Install the input tube seal ring (4) and the inner tube O-ring seal (5).
45. Install the input shaft pilot hub (6) on the input shaft inner tube (3).
46. Install the input hub gasket (1) in the end cover aligning the bolt holes.
47. Install the input shaft inner tube and hub in the end cover. Ensure that the roll pins line up with the slots in the end cover.

Important: New bolts must be used. Reusing old bolts may cause insufficient torque retention. A hand wrench or torque wrench must be used when tightening and torquing these bolts. Using a power tool will generate excess heat in the fastener causing an incorrect torque.

48. On 1st design install new external input shaft hub retaining bolts (1) in the end cover.

Tighten
Tighten the 1st design external input shaft hub bolts to 12 N·m (9 lb ft).

49. On 2nd design install the internal TORX® input shaft hub retaining bolts (2) in the end cover.

Tighten
Tighten the 2nd design internal TORX® input shaft hub bolts to 5 N·m (44 lb in).

Important: Do not use force as the tube can bend easily. Rotate the shafts to align the tubes.

50. Install the end cover to the transaxle case. Insert the input and output shaft tubes into the ends of the shafts and lower the cover. If the cover does not seat, turn the input and output shafts to help align the tubes with the bushings in the shafts.

Important: Clean and lubricate the fasteners with Saturn transaxle fluid. Wipe off excess fluid.

51. Install the end cover to the case bolts and tighten using the tightening sequence.

Tighten
Tighten the end cover-to-case bolts to 28 N·m (21 lb ft).

52. To verify proper assembly, aircheck the clutches and the servo before installing the valvebody.
53. Turn the transaxle, valvebody side up.

Notice: Prior to using the seal installer SA9113T inspect the tool for any nicks or burrs that may damage the seal lip.

54. Apply Loctite 515® Gasket Eliminator sealant Saturn P/N 21005993 or equivalent to the area of the seal that mates to housing and install the converter housing axle seal using axle seal installer driver handle included SA9113T.

Important: Clean and lubricate the fasteners with Saturn transaxle fluid. Wipe off excess fluid.

55. Install 2 converter housing to the case bolts.

Tighten
Tighten the case-to-converter housing short bolts to 25 N·m (18 lb ft).

56. Install the drain plug.

Tighten
Tighten the transaxle drain plug to 30 N·m (22 lb ft).

57. Air check the reverse/servo piston assembly.
58. Install the manual valve link in the manual valve and install the valvebody assembly. The valvebody has two dowel bolts that assist in aligning the valvebody to the case. For reference, the bolts are identified in the illustration below:

• | (1) Valve body-to-case dowel bolts

• | (2) Upper-to-lower valvebody dowel bolts

• | (3) Bolt holding upper and lower valvebody

59. Lower the valvebody and insert the manual link into the manual valve.

Important: Clean and lubricate the fasteners with Saturn Transaxle Fluid. Wipe off excess fluid and install.

60. Torque the valvebody-to-case bolts in the sequence shown below.

Tighten
Tighten the valvebody assembly bolts to 11 N·m (8 lb ft).

Important: While adjusting the transaxle range switch, always rotate the switch towards the engine to achieve continuity. A diagnostic trouble code DTC P0706 could result if this procedure is not followed.

Important: Digital volt/ohmmeter (DVOM) with audible continuity test is preferred. Do not stick a probe in the transaxle range switch terminal hole. Use the male terminals on the transaxle range switch or faulty readings could occur.

61. Adjust the transaxle range switch.

61.1. | Place the transaxle in Drive (D). Use an ohmmeter or continuity tester to check for continuity across terminals on the selector switch. Rotate the transaxle range switch from the left fender towards the engine until continuity is achieved.

61.2. | Tighten the switch-to-case bolts. After the switch-to-case bolts have been tightened, recheck continuity.

Tighten
Tighten the transaxle range switch-to-case bolts to 14 N·m (10 lb ft).

62. Clean the transaxle case and the valvebody cover sealing surfaces with Saturn choke and brake cleaner or equivalent, applied with a clean shop towel.

Important: Install the new gasket during assembly.

63. Align the valvebody cover gasket on the valvebody cover and install on the transaxle case.
64. When installing the valvebody cover, make sure to properly tighten the valvebody cover bolts using the tightening sequence shown.

Tighten
Tighten the valvebody cover-to-case bolts to 12 N·m (9 lb ft).

Important: Clean and lubricate the fasteners with Saturn transaxle fluid. Wipe off the excess fluid and install.

65. Verify the torque of the valvebody cover bolts to account for gasket relaxation using the tightening sequence shown.

Tighten
Tighten the valvebody cover-to-case bolts to 12 N·m (9 lb ft).

66. Install the input shaft to converter O-ring on the input shaft, if a new O-ring has not already been installed during input shaft assembly. Make sure the O-ring sits in the groove furthest from the input shaft splines.
67. Check the converter end play using SA9163T .

67.1. | Install the tool down into the converter and tighten so that the end of the tool will hold onto the splines inside the converter.

67.2. | Set up the dial indicator to the end of the tool.

End Play
Standard 0.00-0.60 mm (0.000-0.26 in)

68. Install the converter pump hub O-ring seal and install the torque converter. Rotate and support the converter to align the input shaft spline and pump drive slots to the converter.
69. Rotate the converter so that the paint dot is down.
70. Place a clean magnet onto the new filter.

Notice: Install the filter by hand. Do not use any type of tool that will scratch, dent, or damage the filter. If the filter is damaged in any way, it must be replaced with a new filter.

71. Using Saturn transaxle fluid, lube the filter seal. Install the transaxle pressure filter.

Tighten
Follow the tightening instructions on the filter label.

72. Install the transaxle temperature sensor and tighten.

When installing sensor, use Saturn sealant with Teflon® Saturn P/N 21485278 or equivalent on the threads.

Tighten
Tighten the transaxle fluid temperature sensor-to-case to 8 N·m (71 lb in).

73. Install the cooler line fittings if removed.

Tighten
Tighten the transaxle cooler line fitting-to-case to 25 N·m (18 lb ft).

Important: Clean and lubricate the input speed sensor with Saturn transaxle fluid. Wipe off the excess fluid.

74. Install the input speed sensor and tighten.

Tighten
Tighten the input speed sensor (ISS) to 26 N·m (19 lb ft).

75. Install the vehicle speed sensor and tighten.

Tighten
Tighten the output speed sensor (OSS) to 26 N·m (19 lb ft).

Important: Clean and lubricate the fasteners with Saturn transaxle fluid. Wipe off excess fluid and install.

76. Install the transaxle fluid fill tube. Tighten the retaining bolt.

Tighten
Tighten the transaxle oil indicator tube-to-case bolt to 12 N·m (9 lb ft).

77. After rebuilding a transaxle the PCM transaxle adaptives should be reset using the service stall system or scan tool. Follow the learn-in procedure located at the beginning of the diagnostic charts in this service manual.