Transmission Assemble

Transmission Assemble

Special Tools

* DT 47678 - Transmission Holding Flange

* DT 47678-10 - Transmission Holding Flange Adapter

* DT 49293 - Gear Select/Skip Shift Solenoid Socket

* J 08614A - Pinion Flange Holder and Remover

* J 3289-20 - Holding Fixture

* J 36017 - Valve Seal Remover

* J 36850 - Transjel(R) Lubricant Assembly Lube

* J 38205-1 - Press Tube

* J 39441-20 - Fifth Gear Installer Adapter

* J 39441-30 - 5th/6th Driven Gear Installer

* J 39442 - Mainshaft and Countershaft Press Adapter

* J 44395 - Transmission Holding Fixture

For equivalent regional tools, refer to Special Tools Special Tools and Equipment.

Shift Shaft Assemblies and Gear Clusters Installation

1. Lubricate all components as assembly progresses, using J 36850 - transjel(R) lubricant.





2. Install the input shaft (1) in the clutch housing.

3. Install the 4th gear blocking assembly:

1. Install the 4th speed drive gear inner cone (4).

2. Install the 4th speed drive gear outer cone (3).

3. Install the 4th speed drive gear blocking ring (2).





Note:
In order for the shift forks to properly line up with the synchronizers, the shift shaft assembly must be assembled correctly. Refer to Shift Shaft and Fork Assemblies Assemble Shift Shaft and Fork Assemblies Assemble.

4. Assemble the shift shaft to the mainshaft.

5. Install the mainshaft and the shift shaft assembly into the clutch housing.





6. Install the countershaft assembly using the following sequence:

1. Lift up the mainshaft assembly enough in order to install the countershaft assembly.

2. Install the countershaft assembly.

3. Lift the mainshaft assembly enough in order to rotate the input shaft to engage the synchronizer keys with 4th gear blocking ring.





7. Install the 5th/6th and the reverse shift shaft.

Align the slots of the shift shaft levers with the interlock plate.

Oil Filter Installation





1. Attach the J 36017 - remover (1) within the groove at the base of the oil filter assembly. Slide the collar (2) of the tool down to grasp the oil filter assembly.





2. Place the oil filter assembly with J 36017 - remover (2) attached onto the clutch housing.

3. Using the J 39442 - adapter (1), tap the oil filter assembly into place with a hammer. Remove the J 36017 - remover.

Transmission Case Installation





Note:
Lubricate all components as the assembly progresses. Use J 36850 - transjel(R) lubricant or the equivalent.

1. Apply sealant GM P/N 12345739, (Canadian P/N 10953472) or equivalent to the transmission case to adapter plate mating surface.





2. Do the following in order to install the transmission case and the select control lever assembly:

1. Shift the transmission into NEUTRAL in order to keep the 3rd/4th shift shaft from engaging.

2. Install the select control lever assembly (2), through the transmission case opening, while sliding the transmission case (1) onto the gear clusters and the shift rail components.

3. Install the select control lever assembly pin (3).





3. Apply threadlock GM P/N 12346004, (Canadian P/N 10953480) or equivalent to the threads of the shift lever guide bolts.





Caution:
Refer to Fastener Caution Fastener Caution.

Note:
In order to align the shift interlock plate slot with the shift lever guide bolt holes, pull up on the 5th/6th and reverse shift rail assembly while installing the shift lever guide bolts.

4. Install the shift lever guide bolts (1) while pulling up on 5th/6th and reverse shift rail assembly. Tighten the bolts to 27 Nm (20 lb. ft).





5. Install the clutch housing to transmission case bolts (1) and tighten to 48 Nm (36 lb. ft).





6. Install the magnets (1) into the transmission case.





7. Install the shift detent assembly (1) and tighten to 40 Nm (30 lb. ft).





8. Using DT 49293 - socket (2), install the gear select/skip shift solenoid (1) and tighten to 40 Nm (30 lb. ft).

5th/6th Speed Driven Gear Installation





1. Install two spacers, caged needle bearing, and 6th driven gear.





2. Install the speed drive gear inner cone, speed drive gear friction cone, and synchronizer blocking ring.





3. Install the synchronizer hub assembly (2) using J 38205-1 - tube (1).





4. Install the following components:

* Drive gear inner cone

* Drive gear friction cone

* Synchronizer blocking ring

* Synchronizer inserts

* Synchronizer sleeve

* 5th/6th shift fork





5. Install the 5th/6th speed driven gear using the J 39441-30 - installer (2) and J 39441-20 - adapter (1). The smaller outside diameter (OD) of the gear faces down.

Reverse Shift Fork Installation





1. Install the 5th/6th speed shift fork retainer ring.





2. Install the retainer clip to the countershaft.





3. Install the spacer to the countershaft.





4. Install the needle bearing to the countershaft.





5. Install the gear to the countershaft.





6. Install the countershaft retainer and spacer.





7. Install the countershaft gear (1).





8. Install the countershaft retainer ring.





9. Install the two piece thrust washer (3).

10. Install the locking ring (2).

11. Install the reverse shift fork and the synchronizer (1).





12. Install a NEW shift fork retainer ring (2).

13. Install the reverse synchronizer retainer ring (1).

Reverse Speed Gear Installation





1. Install the following parts in order:

1. The reverse gear blocking ring assembly (5), including the following components:

* Reverse gear inner ring (6)

* Reverse gear outer ring (7)

* Reverse gear blocking ring (8)

2. The caged needle bearing (4)

3. The reverse speed gear (3)

4. The thrust washer (2)

5. The retainer ring (1)





2. Install the following parts in order:

1. The spacer (3)

2. The roller bearing (2)

3. The spacer (3)

4. The roller bearing retainer ring (1)





3. Install the following parts in order:

* The locking ball (3)

* The speed sensor rotor (2)

* The snap ring (1)





4. Install the extension housing main shaft bearing race (3).

5. Install the shift shaft extension (2).

6. Install NEW shift guide roll pin (1).





7. Lift up on the shift shaft extension while installing the shift detent roller (3), spring (2) and plug (1). Tighten the plug to 24 Nm (18 lb in).

Extension Housing Assembly Installation





1. Apply sealant GM P/N 12345739, (Canadian P/N 10953472) or equivalent to the extension housing to the transmission case mating surface.





2. Apply thread sealer GM P/N 12346004, (Canadian P/N 10953480) or equivalent to the top 2 extension housing bolts.





Note:
Align the 5th/6th shift shaft to the extension housing bore in order to install the extension housing.

3. Install the extension housing (2).

4. Install the extension housing bolts (1) and tighten to 48 Nm (36 lb ft).





5. Install the propshaft O-ring (1).





6. Install the propshaft transmission yoke (2). Install J 39441-30 - installer (1) onto the transmission yoke. Turn the bolt to install the transmission yoke into the mainshaft.





7. Install the propshaft washer (2) and nut (1).

8. Use the J 08614A - holder (3) and J 08614-20 - bolts (4) to hold the propshaft transmission yoke. Tighten the nut (1) to 136 Nm (100 lb ft)





9. Install the shifter cover plate (2).

10. Install the shifter cover plate bolts (1) and tighten to 20 Nm (15 lb ft).





11. Remove the DT 47678 - flange (2) and DT 47678-10 - adapter.

12. Remove the DT 47678 - flange and DT 47678-10 - adapter from J 3289-20 - fixture (1).