17. Transmission Case Assemble

Transmission Case Assemble

Special Tools
* 7079-2 - Universal Driver Handle - Non-Threaded
* J 8092 - Universal Driver Handle - 3/4 in - 10
* J 24433 - Press Tube
* J 44375 - Assembly Pallet
* J 44376 - Bearing Pusher/Puller
* J 44377 - Input Shaft Anti-Rotation Tool
* J 44381 - Shifter Bearing/Input and Output Bearing Remover
* J 44383 - Countershaft Bearing Installer
* J 44385 - Differential Bearing Race and Seal Installer
* J 44386 - Input/Output Bearing Installer
* J 44387 - Output Shaft Bearing Sleeve Installer and Pin
* J 44389 - Countershaft Bearing Installer
For equivalent regional tools, refer to Special Tools (Tools and Equipment).




1. Install the shift rod and bushing.




2. Install the intermediate shaft needle bearing to the transmission housing using the J
44383 - bearing installer (1) and the 7079-2 - driver handle (2).




3. Install a new shifter shaft bearing flush with the casting in the transmission housing, using the J 44381 - bearing remover (1) and the 7079-2 - driver handle (2).





Note: Do not over apply the threadlocker to the bolt threads.

4. Apply GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the reverse lockout lever bolt threads.

Caution: Refer to Fastener Caution (Fastener Caution).

Note: The spring (2) fingers must be positioned on either side of the lever (3).

5. Install the reverse lockout lever (3), spring (2), and the bolt (1) to the transmission housing, if equipped and tighten the bolt to 6 Nm (53 lb in).




6. Install a new differential bearing race to the transmission housing using the J 44385 - seal installer (2) and the 7079-2 - driver handle (1).




7. Install a new differential side bearing race seal to the transmission housing using the J 44385 - seal installer (2) and the 7079-2 - driver handle (1).




8. Install the countershaft bearing to the clutch housing using the J 44386 - bearing installer (1) and the 7079-2 - driver handle (2).
9. Install a new snap ring.




10. Install the input shaft bearing to the clutch housing using the J 44381 - bearing remover (2) and the 7079-2 - driver handle (1).




11. Install the output shaft bearing race and bolts using the J 44387-1 (2), J 44387-2 (3), and the J 8092 - driver handle (1) and tighten the output shaft bearing race bolts to 12 Nm (106 lb in).




12. Install a new differential bearing race to the clutch housing using the J 44385 - seal installer (2) and the J 8092 - driver handle (1).





Note: If either the case or shifter detent is damaged, it may be necessary to install a new shifter detent and/or case.

13. Install the shifter detent into the case if necessary.




14. Install a new differential output shaft seal to the clutch housing using the J 44385 - seal installer (2) and the J 8092 - driver handle (1).





Note: New change makes it unnecessary to remove snap rings from bearings. Removal of snap rings from bearing destroys the ring. New snap rings are sold with bearings.

15. When removed, the bearing will retain their snap rings. If purchased NEW, bearing will come with snap ring already installed to bearing.
16. Install the input shaft and output shaft bearings with snap rings into the transmission housing using the J 44385 - seal installer (2) and the 7079-2 - driver handle (1).




17. Install the shift forks and the input shaft and output shaft onto the J 44375 - assembly pallet.




18. Install the countershaft and the shift fork onto the J 44375 - assembly pallet.
19. Rotate the shaft to verify all gears are properly meshing.




20. Install the housing onto the shift forks and the shafts on to the J 44375 - assembly pallet. Line up the shift forks and the shafts with the housing.





Note: Install the transaxle case to the shafts evenly using the J 44376 - pusher/puller.

21. Install the transaxle case to the shafts using the J 44376 - pusher/puller.




22. Shift the transmission into 4th and 5th gear using a screwdriver in an upward direction.
23. Apply GM P/N 1234549 (Canadian P/N 10953488) or equivalent to the input and output shaft bolts.
24. Install NEW input and output shaft bolts while holding the transmission into 4th and 5th gear in an upward direction and tighten the shaft bolts to 110 Nm (81 lb ft).





Note: If shimming is required, refer to Shimming Procedures (18. Shimming Procedures) before installing the cover.

25. Install sealant GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the rear cover.





Note: The oil guide only installs in one direction. Ensure the oil guide is completely seated in the gear shafts.

26. Install the oil guide.
27. Install the rear cover.
28. Install the rear cover bolt and tighten to 25 Nm (18 lb ft).




29. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the backup lamp switch.
30. Install the backup lamp switch into the transaxle case and tighten to 18 Nm (13 lb ft).




31. Turn the transaxle case and the J 44375 - assembly pallet over on the table.
32. Remove the J 44375 - assembly pallet from the gear shafts and the shift forks.




33. Install the oil tube into the transaxle case.




34. Install the shift rod to the shift fork.





Note: Use only the approved sealer for the transaxle case to shifter cover mating surface.

35. Apply sealer GM P/N 12378516 (Canadian P/N 88900757) or equivalent to the transaxle case to shifter cover mating surface.




36. Install the shifter and the shifter retaining bolts and tighten to 25 Nm (18 lb ft).
Install all possible shifter bolts with the shifter in the neutral position. Install the last shifter bolt in gear and then shift the transmission back into neutral.




37. Shift the transmission into neutral.
38. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the shifter guide bolt.

Caution: Hand start and tighten the shifter guide bolt to avoid damaging the shift lever.

39. Install the shifter guide bolt and tighten to 25 Nm (18 lb ft).




40. Install the differential into the transaxle case.





Note: The step in the roller bearing faces opposite of the pinion gear.

41. Install the roller bearing onto the output shaft.




42. Install the magnet into the transaxle case.




43. Apply sealant GM P/N 12378516 (Canadian P/N 88900757) or equivalent to the transaxle case to clutch housing mating surface.




44. Install the clutch housing to the transaxle case.




45. Install the countershaft into the clutch housing bearing using the J 44389 - bearing installer.




46. Install the clutch housing to transaxle case bolts and tighten the housing bolts to 27 Nm (20 lb ft).




47. Turn the transmission over.
48. Install the transaxle case to clutch housing bolts and tighten the housing bolts to 27 Nm (20 lb ft).




49. Turn the transmission so the shifter is on top.
50. Shift the transmission into any gear.




51. Install the actuator and tube.
52. Install the actuator and tube bolts and tighten to 10 Nm (89 lb in).




53. Apply GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the transmission drain plug.
54. Install the transmission drain plug and tighten to 38 Nm (28 lb ft).




55. Install the transmission fill cap.




56. Hold the input shaft with the J 44377 - tool.
57. Apply GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the intermediate shaft bolt.
58. Install the bolt in the intermediate shaft and tighten to 95 Nm (70 lb ft).




59. Install a new plastic oil guide into the intermediate shaft.





Note: Ensure not to press the sealing cap past the bottom of the chamfer.

60. Use J 24433 - press tube to install a new intermediate shaft sealing cap.




61. Apply GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the vehicle speed sensor bolt.
62. Install the vehicle speed sensor, seal, and bolt and tighten the bolt to 12 Nm (8 lb ft).




63. Install the shift cable bracket (4), the isolators (3), the spacers (2) and the bolt (1) and tighten the shift cable bracket bolt to 20 Nm (15 lb ft).