Transmission Assemble
Transmission Assembly^ Tools Required
^ J 36183 Input Shaft Press Tube and Cap
^ J 36184 Adapter Press Tube Reducer
^ J 36511 Oil Plug Hex Bit
^ J 36515 Assembly Pallet
^ J 36515-15 Mainshaft Adapter
^ J 36515-16 Countershaft Adapter
^ J 36824 Transmission Adapters
^ J 38807 Main Drive Gear Bearing Retainer Seal Installer
^ J 39924-1 Reverse Drag Seal Installer
^ J 39924-2 5th Gear Drag Seal Installer
^ J 6133-01 Speedometer Rotor Installer
^ J 36190 Driver Handle
^ J 36503 Output Shaft Oil Seal Installer
^ J 36506 5th and Reverse Detent Bushing Remover/Installer
^ J 36507 Detent Bushing Remove/Installer
^ J 36798 Shift Shaft Bushing Installing Tool
Important: When installing the main drive gear bearing retainer oil seal, ensure the lip of the oil seal is installed toward the installing tool J 38807.
1. Using J 38807, install the oil seal into the main drive gear bearing retainer.
2. Using J 36183 and J 36184, install the input shaft bearing. Press the bearing until the snap ring is seated.
3. Using J 36511 and J 36507, install the shift shaft front housing bushings.
4. Using J 36507, install the two detent plunger bushings.
5. Install the first bushing to the area where the second scribe mark on the tool is aligned with the housing.
6. Install the second bushing to the area where the first scribe mark on the tool is aligned with the housing.
7. Install the transmission vent.
8. Using J 36511 install the oil drain plug.
Apply sealant to the drain plug threads.
^ Tighten the drain plug to 60 Nm (44 ft. lbs.).
9. Using J 36506 and J 36190, install the rear housing shift shaft bearing.
1. The writing on the bearing lip should face down.
2. Install the bearing flush with the housing surface.
10. Install 2 dowel pins in the housing flange. Drive the dowel pins rearward and flush with the flange surface.
11. Using J 36503, install the slip yoke oil seal.
12. Fill the space between the seal lips with chassis grease.
13. Lubricate all the reverse idler gear parts with Synchromesh Transmission Fluid. Assemble the reverse idler gear using the following procedure:
14. 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.
15. Install the thin flat washer.
16. Install the wave washer.
17. Install the locating ball.
18. Install the thrust washer.
19. Install the bearing assembly.
20. Install the reverse Idler gear.
21. Install the locating ball.
22. Install the thrust washer.
23. Install the snap ring. Set the reverse idler gear assembly aside.
24. Using J 39924-2 and J 36183, install the 5th speed gear drag seal.
25. Using J 39924-1, install the reverse speed gear drag seal.
26. Install the reverse speed gear needle bearing (1).
27. Install the reverse speed gear (2).
28. Install the 5th/Reverse speed gear synchronizer.
1. Check the scribe marks for the correct positions.
2. Position the spiral lock ring towards the reverse speed gear.
3. Manually align and engage the splines.
4. Using J 36183 and J 36184, press the synchronizer until seated.
5. Remove all the metal shavings.
29. Install a new mainshaft snap ring.
30. Install the 5th speed gear needle bearing (1).
31. Install the synchronizer ring (2).
32. install the 5th speed gear (3).
33. Install the 1st speed gear needle bearing assembly
Important: The groove on the outside of the synchronizer sleeve must go towards the 2nd speed gear. This prevents gear clash during 1st and 2nd speed gear shifts. The teeth of the sleeve have different angles.
34. Install the following components:
1. The 1st speed gear (1).
2. The synchronizer interim ring (2) with the teeth up
3. The reactor cone (3) with the flat side towards 1st gear
4. The blocker ring (4) with the teeth down
5. The synchronizer cone (5) with the flat side down
35. Check the 1st/2nd speed gear synchronizer assembly scribe marks for correct positions.
36. Install the 1st/2nd speed gear synchronizer assembly with both synchronizer rings.
1. Using J 36183 and J 36184, manually align and engage the splines.
2. Start the press operation.
1. Stop pressing before the tangs engage.
2. Lift and rotate the gear.
3. Engage the synchronizer ring.
3. Press the synchronizer until seated.
4. Remove all the metal shavings.
37. Install the following components:
1. The synchronizer cone with the flat up
2. The blocker ring with the tangs up
3. The reaction cone with the wide flat portion up
4. The interim ring
38. Install the following components:
1. The 2nd speed gear needle bearing (2).
2. The 2nd speed gear (1).
Ensure that the synchronizer ring gear teeth are positioned toward the 1st gear.
39. Install a new mainshaft snap ring.
40. Install the following components:
1. The 3rd speed gear needle bearing (1).
2. The 3rd speed gear (2).
3. The synchronizer ring (3).
41. Install the following components:
1. The 2nd speed gear 2-piece thrust washer. Ensure that the dots are facing up.
2. The retainer ring. Ensure that the retainer ring is installed around the washer.
42. Check the 3rd/4th speed gear synchronizer assembly scribe marks for correct positions.
43. Install the 3rd/4th speed gear synchronizer assembly with both synchronizer rings. Ensure that the groove in the synchronizer ring faces upward.
1. Using J 36183 and J 36184 manually align and engage the splines.
2. Start the press operation
1. Stop pressing before the tangs engage.
2. Lift and rotate the gear.
3. Engage the synchronizer ring.
3. Press the synchronizer until seated.
4. Remove all the metal shavings.
44. Install the mainshaft snap ring.
45. Install the following parts on the assembly fixture J 36515-15 and J 36515 :
1. The input shaft (1)
2. The pilot bearing (2). Ensure the small diameter of the bearing is positioned toward the input shaft.
3. The synchronizer ring (3)
4. The mainshaft assembly (4)
46. 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)
47. Install the following components:
1. The output shaft bearing assembly (2)
2. A new mainshaft snap ring (1)
48. Using J 6133-01, install the reluctor wheel onto the main shaft.
49. Install the countershaft bearing.
^ Use TRANSJEL or equivalent in order to retain the bearing.
^ The smaller diameter of the bearing cage is positioned toward the housing.
50. Install the rear housing assembly. Ensure the reverse idler shaft is positioned with the hole in the housing.
51. Apply sealant GM P/N 1052080 or equivalent to the bolt holes of the rear housing.
52. Install the three rear bearing retainer bolts.
Apply threadlocker GM P/N 12345382 to the bolt threads.
^ Tighten the rear bearing retainer bolts to 22 Nm (16 ft. lbs.).
53. Remove the rear housing from J 36515, J 36515-15, and J 36515-16.
54. Apply sealant GM P/N 1052080 or equivalent to the bolt hole.
55. Install the following components:
1. The idler shaft support
2. The idler shaft bolts. Apply threadlocker GM P/N 12345382 or equivalent to the bolt threads.
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 the bolt to 22 Nm (16 ft. lbs.).
56. Install the 3rd/4th speed gear shift fork onto the 3rd/4th speed gear synchronizer sleeve. Align all three insert notches.
57. 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).
58. Slide the shift shaft all the way into the housing.
59. 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. Ensure the roll pin holes are aligned and horizontal.
2. Support the shift shaft while installing the roll pin.
3. Install the roll pin flush with the shift lever.
60. 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.
Important: Excessive force peens the shift shaft and damages the shift shaft bearing causing increased shift effort.
Important: Use the rear roll pin hole (2) on transmissions to be installed on SIT (small) trucks.
61. Use the front roll pin hole (1) on transmissions to be installed on C/K (large) trucks.
62. Install the shift shaft and shift shaft socket and roll pin.
1. Align the holes in the shift shaft socket and the shift shaft.
2. Drive the roll pin flush with the bottom of the shift shaft socket.
Important: The smaller diameter of the bearing cage goes into the bearing race.
63. Install the countershaft bearing onto the counter shaft. Ensure the smaller diameter side of the bearing is positioned toward the front case half.
64. Install the front housing to the rear housing.
65. 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.
66. Install the housing bolts. Do not tighten the bolts.
Important: Do not allow sealant into the oil return hole in the housing or beating retainer.
67. Apply RTV GM P/N 1052943 or equivalent to the inside edge of the bearing retainer mating surface.
68. Install the input shaft bearing retainer to the housing with six bolts.
^ Align the retainer oil drain hole with the drain hole in the housing.
^ Tighten the retainer bolts to 14 Nm (10 ft. lbs.).
69. Install the following components:
1. The shift shaft detent plunger
2. The shift shaft detent spring
3. The shift shaft detent plug
Apply sealant GM P/N 1052080 or equivalent to the detent plug.
70. Coat the speed sensor O-ring with Synchromesh Transmission Fluid GM P/N 12345349 or equivalent.
71. Install the speed sensor, O-ring, and bolt.
^ Tighten the bolt to 9 Nm (80 inch lbs.).
72. Install the backup lamp switch.
^ Apply sealant GM P/N 1052080 or equivalent to the threads of the backup lamp switch.
^ Tighten the switch to 14 Nm (10 ft. lbs.).
73. Install the shift shaft block-out bushing pin.
^ Tighten the bolt to 25 Nm (18 ft. lbs.).
74. Fill the transmission to the bottom of the fill plug with Synchromesh Transmission Fluid GM P/N 12345349 or equivalent.
75. Using J 36511 install the oil fill plug.
^ Tighten the oil fill plug to 60 Nm (44 ft. lbs.).