Assembly
Input Shift Bearing Retainer AssemblyInstallation Procedure
Tools Required
J 38807 Main Drive Gear Bearing Retainer Seal Installer
Install the oil seal into the main drive gear bearing retainer. The lip of the seal goes toward the installing tool. Use the J 38807.
Rear Housing Assembly
Tools Required
- J 36190 Driver Handle
- J 36503 Output Shaft Oil Seal Installer J 36506 5th and Reverse Detent Bushing Remover/Installer
1. Install the rear housing shift shaft bearing. Use J 36506 and J 36190.
1. The writing on the bearing lip should face down.
2. Install the bearing flush with the housing surface.
2. Install 2 dowel pins in the housing flange.
Drive the dowel pins rearward and flush with the flange surface.
3. Install the slip yoke oil seal. Use J 36503.
4. Fill the space between the seal lips with chassis grease. Use GM P/N 1052497 or equivalent.
Front Housing Assembly
Tools Required
- Hydraulic Press
- J 36183 Input Shaft Press Tube with Cap
- J 36184 Adapter Press Tube Reducer
- J 36510 Clutch Fork Pivot Remover/Installer
- J 36507 Detent Bushing Remove/Installer
- J 36511 Oil Fill Plug Hex Bit (17 mm)
- J 36798 Shift Shaft Bushing Installing Tool
- J 36190 Driver Handle
1. Install the input shaft bearing.
- Press in the bearing until the snap ring is seated.
- Use tool J 36183 and tool J 36184.
- Use a hydraulic press.
2. Install the shift shaft front housing bushings. Use J 36798 and J 36190.
3. Install the two detent plunger bushings. Use tool J 36507.
4. Install the first bushing until the second scribe mark on the tool is aligned with the housing.
5. Install the second bushing until the first scribe mark on the tool is aligned with the housing.
6. Install the transmission housing vent assembly.
7. Apply pipe sealant with Teflon GM P/N 1052080 or equivalent on the fill plug threads.
8. Install the oil fill plug. Use J 36511.
Tighten
Tighten the fill plug to 60 N.m (44 lb ft).
9. Apply pipe sealant with Teflon GM P/N 1052080 or equivalent to the drain plug threads.
10. Install the oil drain plug. Use tool J 36511.
Tighten
Tighten the drain plug to 60 N.m (44 lb ft).
Reverse Idler Gear Assembly
1. Lubricate all the parts as the assembly progresses. Use Synchromesh Transmission Fluid GM P/N 12345349 or equivalent.
2. Install the snap ring on the short side of the shaft. The short side of the shaft is on the same end of the shaft as the chamfered gear.
3. Install the thin flat washer.
4. Install the wave washer.
5. Install the locating ball.
6. Install the thrust washer.
7. Install the bearing assembly.
8. Install the reverse Idler gear.
9. Install the locating ball.
10. Install the thrust washer.
11. Install the snap ring.
Transmission Assembly
Tools Required
- J 3289-20 Base Holding Fixture
- J 6133-01 Speedometer Rotor Installer
- J 8763-02 Holding Fixture C-Clamp
- J 8763-21 Balance Bracket for C-Clamp
- J 25070 Heat Gun
- J 36515 Assembly Pallet
- J 36515-10 Retainer Alignment Cable (2WD Models Only)
- J 36515-15 Mainshaft Adapter
- J 36515-16 Countershaft Adapter
- J 36824 Transmission Adapters
- J 36511 Oil Fill Plug Hex Bit (17 mm)
Important: Some parts require an assembly lubricant. Use TRANSJEL or equivalent.
1. Install the pilot bearing into the input shaft.
- Turn the small diameter of the bearing cage toward the input shaft. Retain the bearing with TRANSJEL or equivalent.
2. Install the following parts on the assembly fixture J 36515-15 and J 36515:
1. The input shaft (1)
2. The pilot bearing (2)
3. The synchronizer ring (3)
4. The mainshaft assembly (4)
3. Install the following parts on the mainshaft and on the assembly fixture J 36515-16:
1. The countershaft assembly (1)
2. The reverse idler assembly (2)
3. The 1st/2nd speed gear shift fork (3)
4. The 5th/reverse speed gear shift fork (4)
4. Install the following components:
1. The output shaft bearing assembly (2)
2. A new mainshaft snap ring (1)
5. Heat the reluctor wheel for 7- 10 minutes at 120 °C (250 °F).
Important: Before assembly, heat the bore of the rear main housing output shaft bearing.
6. Install a new vehicle speed sensor reluctor wheel. Use J 6133-01, if necessary.
Important: Press each bearing roller towards the race. This will secure them for easier assembly.
7. Install the countershaft bearing.
- Use TRANSJEL or equivalent in order to retain the bearing.
- The smaller diameter of the bearing cage goes into the bearing race of the housing.
8. Install the following components:
1. J 36515-10 through the bolt-holes in the rear housing
2. Screw the threaded cable ends into the output shaft bearing retainer (1).
3. Position the notch in the bearing retainer towards the oil delivery tube assembly (2).
9. Heat the rear main housing bore 3-5 minutes.
Use J 25070.
Important: Bring the housing straight down. If you feel resistance at about 7mm (1/4 in), then the counter shaft bearing rollers are cocked. Repeat the procedure. Do not force the housing down.
10. Install the rear housing assembly.
1. Make sure to line up the reverse idler shaft with the hole in the housing.
2. Rotate the housing back and forth while pushing down.
3. Pull up on J 36515-10 while installing the rear housing.
11. Apply pipe sealant with Teflon GM P/N 1052080 or equivalent to the bolt holes of the rear housing.
12. Apply GM P/N 12345382 thread locker to the bolt threads.
13. Install one rear bearing retainer bolt in the open hole. Do not tighten the bolt. This will hold the bearing retainer plate in place when the cables are removed.
14. Remove one J 36515-10 at a time and replace with bearing retainer bolts.
Tighten
Tighten the rear bearing retainer bolts to 22 N.m (16 lb ft).
15. Lay the rear housing assembly down on the workbench. Remove J 36515 , J 36515-15, and J 36515-16 from the housing.
16. Apply pipe sealant with Teflon GM P/N 1052080 or equivalent to the bolt-hole.
17. Apply GM P/N 12345382 thread locker or equivalent to the bolt threads.
18. Install the following components:
1. The idler shaft support
2. The idler shaft bolts
3. Line up the bolt threads in the idler shaft support with the bolt hole.
4. Hold the reverse idler shaft against the idler support while tightening the bolts.
Tighten
Tighten the bolt to 22 N.m (16 lb ft).
19. Install J 5763-21, J 8763-02, and J 36824 on the transmission housing.
20. Install the 3rd/4th speed gear shift fork onto the 3rd/4th speed gear synchronizer sleeve. Align all three insert notches.
21. Slide the shift shaft through the following parts:
1. The 3rd/4th speed gear shift fork. Ensure that the detent reliefs in the shift shaft point out (1).
2. The shift lever (2).
3. The block-out bushing (3).
4. The 1st/2nd speed gear shift fork (4).
5. The shift socket (5).
22. Slide the shift shaft all the way into the housing.
23. Install a new short roll pin into the shift lever. The end of the spiral must face toward the direction of the thrust.
1. Rotate the shift shaft and the shift lever/block-out bushing assembly. Make sure the roll pin holes are aligned and horizontal.
2. Support the shift shaft while installing the roll pin.
3. Install the roil pin flush with the shift lever.
24. Install the detent spring and the ball plunger into the hole in the shift lever.
1. Rotate the shift shaft counterclockwise. The shift lever should be almost into the 5th/Reverse speed gear insert notch.
2. Install the spring (1) and the ball plunger (2) into the shift lever.
3. Rotate the shift shaft until the shift lever aligns with the 3rd/4th speed gear insert.
Notice: Excessive force peens the shift shaft and damages the shift shaft bearing. This causes increased shift effort.
Important: Use the rear roll pin hole on the M50 (S/T) transmission and the M65 (C/K) transmission.
25. Install the long shift socket roll pannes end of the spiral must face the direction of the thrust.
1. Align the holes in the shift socket and the shift shaft.
2. Drive the roll pin flush with the bottom of the shift socket.
26. Apply gasket maker GM P/N 1052943 or equivalent to both sides of the isolator plate.
27. Install the isolator plate onto the housing.
The thin side of the plate should be on the left side of the transmission housing.
28. Install the shift lever.
29. Install 4 bolts.
Tighten
Tighten the bolts to 8.5 N.m (75 lb in).
Important: The smaller diameter of the bearing cage goes into the bearing race.
30. Install the countershaft bearing in the front housing.
1. Apply TRANSJEL or equivalent on the bearing rollers.
2. Press each bearing roller into the cage.
3. Apply TRANSJEL or equivalent to the bearing race on the input shaft.
Important: Bring the housing straight down. If you feel resistance at about 7 mm (1/4 in), then the rollers are cocked. Repeat the procedure. Do not force down the housing.
31. Install the front housing.
32. Install a new snap ring on the input shaft. It may be necessary to pull out on the input shaft in order to install the snap ring.
33. Rotate the transmission to a horizontal position. Install the 2 housing dowel pins.
Drive the dowel pins into the front housing flange.
34. Install the housing bolts. Bolts behind the holding fixture can not be installed at this time.
- Do not tighten the bolts.
- Tip the transmission vertically.
Important: Do not allow the gasket maker material to plug the oil return hole. This reduces oil flow through the input shaft bearing. Premature bearing failure could result.
35. Apply gasket maker GM P/N 1052943 or equivalent to the inside edge of the bearing retainer bolt hole pattern.
36. Install the following components:
1. The input shaft bearing retainer assembly (Align the oil drain back hole with the hole in the housing.)
2. The six bolts
Tighten
Tighten the bolts to 8.5 N.m (75 lb in).
37. Apply pipe sealant to the detent plunger plug. Use pipe sealant with Teflon GM P/N 1052080 or equivalent.
38. Install the following components:
1. The shift shaft detent plunger
2. The shift shaft detent spring
3. The plug (Use a brass drift in order to install the plug.)
39. Coat the vehicle speed sensor O-ring with clean transmission lubricant. Use Synchromesh Transmission Fluid GM P/N 12345349 or equivalent.
40. Install the electronic speed sensor:
1. Use a new O-ring.
2. Install the bolt.
Tighten
Tighten the bolt to 9 N.m (80 lb in).
41. Apply pipe sealant to the threads of the backup lamp switch assembly. Use pipe sealant with Teflon GM P/N 1052080 or equivalent.
42. Install the backup lamp switch assembly.
Tighten
Tighten the switch to 9 N.m (80 lb in).
43. Remove J 8763-02 and J 36824.
44. Install 2 bottom housing bolts.
Tighten
Tighten the bolts to 35 N.m (26 lb ft).
45. Install the shift shaft block-out bushing pin.
Tighten
Tighten the bolt to 25 N.m (18 lb ft).
46. Fill the transmission with lubricant.
1. Refer to Manual Transmission/Transaxle Specifications; Fluid.
2. Use Synchromesh Transmission Fluid GM P/N 12345349 or equivalent.
3. Remove the oil fill plug. Use J 36511.
4. Install the transmission lubricant.
5. Install the oil fill plug.
Tighten
Tighten the oil fill plug to 60 N.m (44 lb ft).