Transmission Clearance Specifications. Saturn RELAY Ext. 2006

For 1990-2009 cars only

Makes 🢒 Saturn 🢒 2006 🢒 RELAY Ext. 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - AF33-5 🢒 Transmission Clearance Specifications

Table 1:	Transmission Clearance Specifications
Table 2:	Clutch Assembly Specifications

Transmission Clearance Specifications

Application	Specification
Application	Metric	English
Front Differential Assembly (13)
Unloaded Rotating Torque	0.70-1.20 N·m	6-11 lb in
Fluid Pump Assembly (2)
Driven Gear (204) to Body Clearance	0.075-0.20 mm	0.002-0.007 in
Drive Gear (205) Tip to Body Clearance	0.013-0.342 mm	0.0005-0.014 in
Driven Gear (204) Tip to Body Clearance	0.004-0.298 mm	0.0001-0.018 in
Fluid Pump Body Bushing, ID	38.113-38.188 mm	1.500-1.503 in
Side Clearance of Drive and Driven Gear to Body	0.03-0.10 mm	0.0012-0.004 in
Stator Shaft Bushing, ID	22.201-22.257 mm	0.874-0.876 in
Front Carrier Sun Gear Assembly (24)
Front Carrier Bushing, ID	30.00-30.076 mm	1.181-1.184 in
Front Sun Gear Bushing, ID	22.200-22.276 mm	0.874-0.877 in
Rear Sun Gear Bushing, ID	22.200-22.276 mm	0.874-0.877 in
2nd Coast Clutch and 2nd Clutch Hub and 2nd Clutch Sprag Assembly (11) to Fluid Pump
Installed Height	51.09-51.71 mm	2.011-2.036 in
Forward and Direct Clutch Assembly (23) End Play
Installed End Play	0.188-0.570 mm	0.007-0.022 in
Forward and Direct Clutch Assembly (23) to Transmission Case (17)
Installed Height	50.850-51.825 mm	2.002-2.040 in
Front Differential Gear Thrust Bearing (263) to case (17)
Installed Height	1.269-1.645 mm	0.050-0.065 in
3rd Gear Band Servo (57) Return Springs
Outer Spring
Free/Relaxed Length	40.2 mm	1.582 in
Outer Diameter	20.3 mm	0.800 in
Inner Spring - yellow
Free/Relaxed Length	13.5 mm	0.531 in
Outer Diameter	10.0 mm	0.394 in
3rd Gear Band Servo (57)
Piston Bore Stroke	5.76-6.76 mm	0.227-0.266 in
Transmission Housing - Torque Converter Distance
Torque Converter mounting lug/pad minimum installed distance to Transmission Housing outer edge	11.35 mm	0.447 in

Clutch Assembly Specifications

Application	Specification
Application	Metric	English
Direct Clutch (562)
Piston Bore Stroke	1.49-1.91 mm	0.059-0.075 in
Relaxed Clutch Pack Stack Up Clearance	0.76-1.24 mm	0.030-0.049 in
Available Direct Clutch Backing Plate (555) Thickness	3.6 mm	0.142 in
	3.8 mm	0.150 in
	4.0 mm	0.157 in
Forward Clutch (565)
Piston Bore Stroke	0.74-1.06 mm	0.029-0.042 in
Relaxed Clutch Pack Stack Up Clearance	0.74-1.06 mm	0.029-0.042 in
Available Forward Clutch Backing Plate (551) Thickness	3.6 mm	0.142 in
	3.8 mm	0.150 in
	4.0 mm	0.157 in
Low and Reverse Clutch (27)
Piston Bore Stroke	1.09-1.91 mm	0.43-0.075 in
Relaxed Clutch Pack Stack Up Clearance	0.43-1.43 mm	0.017-0.056 in
1-2 Reverse Clutch (603)
Piston Bore Stroke	2.34-2.70 mm	0.092-0.106 in
Relaxed Clutch Pack Stack Up Clearance	0.84-1.63 mm	0.033-0.064 in
Available 1-2 Reverse Clutch Backing Plate (621) Thickness	5.0 mm	0.197 in
	5.1 mm	0.201 in
	5.2 mm	0.205 in
	5.3 mm	0.209 in
	5.5 mm	0.216 in
Second Clutch (210)
Piston Bore Stroke	1.10-1.50 mm	0.043-0.059 in
Relaxed Clutch Pack Stack Up Clearance	0.44-1.04 mm	0.0173-0.040 in
Available 2nd Clutch Backing Plate (219) Thickness	3.6 mm	0.142 in
	3.8 mm	0.150 in
	4.0 mm	0.157 in
Second Coast Clutch (222)
Piston Bore Stroke	1.24-1.96 mm	0.049-0.077 in
Relaxed Clutch Pack Stack Up Clearance	0.53-1.59 mm	0.021-0.063 in
4-5 Clutch (582)
4-5 Clutch Housing Bushing, ID	36.125-36.200 mm	1.422-1.425 in
4-5 Clutch Piston Stroke	1.52-1.90 mm	0.060-0.075 in
Relaxed Clutch Pack Stack Up Clearance	0.60-1.36 mm	0.024-0.054 in
Available 4-5 Clutch Backing Plate (567) Thickness	3.6 mm	0.142 in
	3.8 mm	0.150 in
	4.0 mm	0.158 in