Transmission Assemble

^ Tools Required
- J 22873 Mainshaft Bushing Installer
- J 36183 Press Tube
- J 36184 Press Tube Reducer
- J 36190 Universal Drive Handle
- J 36504 Input Shaft Seal Installer
- J 36511 Oil Plug Hex Bit
- J 36798 Shift Rail Bushing Staking Tool
- J 41663 Assembly Pallet
- J 44339 Reverse Synchronizer Installer
- J 44340 Bearing Installer





Important: When installing the front shift shaft bushing into the front housing, ensure the bushing split line is not aligned with the hydrolock in the front housing.

1. Using the J 36798 and the J 36190, install the shift shaft front bushing into the front housing.





Important: When installing the rear shift shaft bushing into the housing bore, ensure the bushing lip faces toward the housing and the bushing is flush with the top of the housing bore.

2. Using the J 36190, install the rear shift shaft bushing into the rear housing.





3. Install the shift shaft support and retaining ring into the rear housing.





Important: Prior to installing the slip yoke oil seal, apply petroleum jelly between the lips of the seal.

4. Using the J 36504, install the slip yoke oil seal into the rear housing.





5. Apply teflon pipe sealant GM P/N 12346004 or equivalent to the threads of the oil drain plug.
6. Using the J 36511, install the oil drain plug into the rear housing.
^ Tighten the oil drain plug to 30 Nm (22 ft. lbs.).





Important:
^ Lubricate all components during assembly.
^ Use lubricant Synchromesh Transmission Fluid Friction Modified GM P/N 12377916 or equivalent.
^ Install the synchronizer sleeves with the offset teeth toward the second, third, and fifth gear. Sleeves are identified with the following marks:
- First and second synchronizer assembly: One groove on the Outer Diameter (OD) of the sleeve goes toward the first gear.
- Third and fourth synchronizer assembly: Two grooves on the Outer Diameter (OD) of the sleeve goes toward the third gear
- Fifth and reverse synchronizer assembly: Two grooves on the Outer Diameter (OD) of the sleeve goes toward the fifth gear and one groove toward the reverse gear.

7. Install the reverse gear onto the output end of the mainshaft

Important: The reverse synchronizer blocking ring should have been marked for identification during disassembly. Ensure the reverse blocking ring being installed is the correct blocking ring. The first gear and fifth gear blocking rings look the same, but are not interchangeable with the reverse blocker ring.

8. Install the reverse gear synchronizer blocking ring.





9. Using the J 44339 (1), install the fifth reverse synchronizer assembly. Ensure the synchronizer hub is seated completely on the mainshaft.





10. Install the fifth reverse synchronizer assembly retainer ring.
11. Install the fifth gear synchronizer blocking ring.
12. Install the fifth gear.





13. Using the J 44340 (1), install the output shaft bearing. Ensure the bearing is completely installed on the mainshaft.
14. Install the output shaft bearing retainer ring to the mainshaft.
15. Install the speed sensor rotor down the mainshaft five centimeters (two inches) from the ball bearing.
16. Using the J 22873, install the speed sensor rotor.





17. Using the J 22873, install the first gear onto the input end of the mainshaft.
18. Install the first gear synchronizer inner cone.
19. Install the first gear synchronizer middle cone.
20. Install the first gear synchronizer blocking rings

Important: Ensure the scribed hub is correctly aligned.

21. Install the first and second gear synchronizer assembly. Align the synchronizer rings with the keys on the first and second gear synchronizer. One synchronizer ring should be on each side of the synchronizer assembly.
22. Install the synchronizer assembly retainer ring. Ensure the retainer ring is installed into the retainer ring slot around the mainshaft.





23. Install the second gear synchronizer blocking ring.
24. Install the second gear synchronizer middle cone.
25. Install the second gear synchronizer inner cone.
26. Install the second gear.





27. Install the two piece split washer, pin, and the retainer ring.





28. Install the third gear.
29. Install the third gear synchronizer blocking ring.
30. Using the J 22873 install the third and fourth gear synchronizer.
31. Install the fourth gear synchronizer blocking ring.
32. Align the synchronizer blocking rings with the keys on the third and fourth gear synchronizer.
33. Install the retainer ring.





34. Install the following components onto the input end of the mainshaft:
34.1. The pocket bearing
34.2. The input shaft





Important:
^ When assembling the reverse idler gear, ensure the chamfer on the segment and the collar are facing up, toward the rear, with the collar on the top.
^ Ensure the groove on the idler gear is toward the collar.

35. Install the following components onto the reverse idler shaft:
35.1. The segment
35.2. The two O-rings
35.3. The caged roller bearings
35.4. The reverse idler gear
35.5. The idler shaft support collar





36. Install the assembled mainshaft onto the J 416 63.
37. Press the countershaft rear ball bearing onto the countershaft.
38. Install the snap ring on to the countershaft.
39. Install the countershaft onto the J 416 63.
40. Install the reverse idler shaft assembly onto the J 41663.





41. Install the output shaft bearing retainer onto the mainshaft and the countershaft.
^ Ensure the output shaft bearing retainer is installed behind the ball bearings on the mainshaft and the countershaft.
^ Ensure the fork end of the output shaft bearing retainer is installed under the countershaft ball bearing.
^ Ensure the hook end of the output shaft bearing retainer is installed under the mainshaft ball bearing.





42. Install the fifth/reverse shift fork onto the first/second shift fork.
43. Install the fork assemblies onto the first/second and fifth/reverse gear sleeves.
44. Install the rear housing over the mainshaft, countershaft and reverse idler shaft assembly.





Important: Two bolts of different length are used to secure the idler shaft segment to the rear housing. The forward (front) reverse idler shaft assembly hole houses the short bolt.

45. Install the two bolts that secure the reverse idler shaft assembly to the rear housing.
Finger tighten the two bolts.

Important: Use new O-rings with the five output shaft bearing retainer to housing bolts.

46. Install the NEW O-rings on the five output shaft to bearing retainer bolts.





Notice: Refer to Fastener Notice in Service Precautions.

47. Install the five output shaft bearing bolts using the following sequence:
47.1. Finger start bolts 1, 2, and 4.
47.2. Finger start bolts 3 and 5.
47.3. Finger tighten the bolts in the following order: 1, 2, 3, 4, 5.
47.4. Tighten the five output shaft bearing retainer to housing bolts in the following order: 1, 2, 3,4,5.
^ Tighten the bolts to 22 Nm (16 ft. lbs.).
47.5. Re-tighten the five output shaft bearing retainer to housing bolts in the following order: 1,2,3,4,5.
^ Tighten the bolts to 22 Nm (16 ft. lbs.).
48. Tighten the reverse idler shaft assembly to housing bolts.
48.1. Tighten the reverse idler shaft assembly to housing rear bolt to 22 Nm (16 ft. lbs.).
48.2. Tighten the reverse idler shaft assembly to housing forward bolt to 44 Nm (33 ft. lbs.).
49. Remove the rear housing assembly from the J 41663. Place the rear housing assembly horizontally.





50. Install the third/fourth fork onto the third and fourth gear synchronizer sleeve.

Important: Ensure the shift lever and block- out bushing are positioned correctly on the shift shaft.

51. Install the shift lever and block-out bushing onto the shift shaft.
52. install the shift shaft through the first-second shift fork and fifth and reverse shift fork.
53. Install the shift socket onto the shift shaft.
54. Slide the shift shaft into the case.
55. Install the roll pin into the shift lever.
^ Rotate the shift shaft and shift lever/blockout bushing assembly until the roll pin holes are aligned and horizontal.
^ Support the shift shaft during installation of the roll pin.
^ Install the roll pin flush with the shift lever.
56. Install the spring and ball plunger into the hole in the shift lever.
^ Rotate the shift shaft counter-clockwise until the shift lever is almost into the fifth-reverse insert notch.
^ Install the spring and plunger into the shift lever.
^ Rotate the shift shaft until the shift lever aligns with the 3-4 insert.





57. Install the 22 mm (0.866 inch) shift shaft lever roll pin into the shift shaft lever. Ensure the roll pin to set flush with the shift shaft lever assembly.
58. Install the shift shaft socket and the 30 mm (1.18 inch) roll pin onto the shift shaft. Ensure the shift shaft socket roll pin is flush with the shift shaft socket hole.





59. Install the shift shaft spring and plunger assembly into the shift shaft lever assembly.

Important: The transmission must be in the 3rd or 4th gear install during the installation of the shift tower. After the shift tower has been installed to the transmission, the shifter can be engaged into other shift installs.

60. Install the transmission into the third gear:
60.1. Center the shift shaft.
60.2. Push the shift shaft all the way to the rear of the rear housing.
61. Apply a thin layer of RTV sealer GM P/N 1052942 to the mating surfaces of the rear housing.
62. Using the J 36183 and the J 36184, install the input shaft ball bearing into the front housing.
63. Install the front countershaft roller bearing into the front housing. Ensure the small end of the countershaft bearing is toward the front housing.





64. Install the front housing onto the rear housing.





65. Install the shift shaft detent blockout bushing pin into the top of the front housing. Install the shift shaft detent blockout bushing pin by hand in order to ensure the detent lock pin installs into the shift shaft lever and the shift shaft bushing.





66. Install the nine bolts securing the front housing to the rear housing.
^ Tighten the nine housing bolts to 33 Nm (24 ft. lbs.).
^ Tighten the shift shaft detent blockout bushing pin to 33 Nm (24 ft. lbs.).





67. Install the following components:
^ The shift shaft detent plunger (1)
^ The spring (2)
^ The detent plug (3)





68. Install the snap ring on the input shaft front ball bearing.
69. Apply a thin layer of RTV sealer GM P/N 12345739 or equivalent to the mating surfaces of the input shaft bearing retainer. Install the input shaft bearing retainer to the front housing.
70. Install the five bolts that secure the input shaft bearing retainer to the front housing.
^ Tighten the bolts that secure the input bearing retainer to 29 Nm (21 ft. lbs.).
71. Install the backup light switch into the rear housing.
^ Tighten the backup light switch to 37 Nm (28 ft. lbs.).
72. Install the speed sensor.
^ Tighten the speed sensor to 17 Nm (12 ft. lbs.).
73. In order to prevent spillage, fill the transmission with oil after installing. Refer to Lubrication Specifications.





74. Using the J 36511, install the oil fill plug into the rear housing.
^ Tighten the oil fill plug to 30 Nm (22 ft. lbs.).