P. Transmission Case Assembly

^ Tools Required:
- J 37357 Countershaft Bearing and Race Remover and Installer
- J 8092 Universal Driver Handle
- J 37372 Synchronizer and Gear Installer
- J 8001 Dial Indicator

ASSEMBLE
1. Front countershaft bearing onto countershaft using J 37357 with J 8092 and a press.
2. Countershaft in case.





3. Rear countershaft bearing to countershaft using J 37372 and a press.

NOTICE: Failure to properly support the Countershaft may result in permanent distortion of the case during installation.
- Support the Countershaft with J 37357.

4. Rear Countershaft bearing race.
5. Rubber O-ring seal and reverse idler gear in case with shift lever groove facing rear of case.
6. Reverse idler shaft from rear of case.
7. Roll pin in idler shaft.





8. Countershaft retainer (without shims) to transmission housing.

Tighten
- Countershaft retainer bolts to 20 N.m (15 lb. ft.).





Measure
- Countershaft end play using dial indicator J 8001.
A. Remove retainer and install shim(s) as necessary to provide proper end play. Zero end play with no preload is idea, but up to 0.10 mm (0.004 in.) end play is allowable. Do not preload bearing with shim(s) larger than the original end play measurement. Refer to "Specifications."
B. Reinstall retainer and bolts.

Tighten
- Bolts to 20 N.m (15 lb. ft.).
- Bend tabs over the four attaching bolts.

9. Reverse shift fork in case.





10. Assembled mainshaft in transmission case.
11. Rear mainshaft bearing race in case.





12. Drive gear in case (make sure rollers, thrust bearing and washer are in place), and engage in 3rd/4th synchronizer sleeve and blocker ring.





13. Front end bearing race in front bearing retainer.
- Do not install shims in front bearing retainer at this time.
- Temporarily install front bearing retainer.
14. 5th gear on countershaft.
- Slide shift rail/5th gear shift fork assembly into case. As shift rail enters case, align reverse shift fork and slide rail through fork. Position lever return spring in case with long end of spring to rear, and slide rail through spring.





15. Blocker ring and 5th gear synchronizer in 5th gear shift fork.





16. 5th gear synchronizer retainer and snap ring.





17. Oiling funnel into rear of countershaft.
18. 5th/reverse shift lever in case.





19. 5th/reverse lever return spring to side of case.
- Make sure reverse shift fork pin and 5th gear shift rail pin are engaged with shift lever.





20. 5th gear/reverse lever pivot bolt and retaining clip.
- Coat pivot bolt threads with pipe thread sealant GM P/N 1052080.

Tighten
- Pivot bolt to 27 N.m (20 lb. ft.).

21. Backup lamp switch.
- Coat threads with pipe thread sealant GM P/N 1052080.
22. Speedometer reluctor ring and retaining clip.
23. Circlip
- Apply 3 mm (0.125 in.) bead of RTV Sealant GM P/N 12345739 to transmission cover assembly.
- Make sure all synchronizers are in the neutral position and that the shift forks in the cover are in the neutral (center) position.
- Lower cover onto case while aligning shift forks and synchronizer sleeves.





24. Cover and install two dowel bolts.
25. Remaining cover bolts.

Tighten
- Cover bolts to 13 N.m (115 lb. in.).
- Apply 3 mm (0.125 in.) bead of RTV Sealant GM P/N 12345739 to extension housing mating surface.
- Coat detent springs with petroleum jelly and insert in offset lever.
- Lubricate detent plate and install detent ball in neutral position on plate.





- Position offset lever in extension housing with spring over detent ball. Slide lever and extension into position as an assembly.

26. Extension housing vent.
- Press downward on offset lever to compress detent spring and push lever and housing into position.





27. Extension housing bolts.
- Apply pipe thread sealant GM P/N 1052080 to threads of bolts.

Tighten
- Extension housing bolts to 30 N.m (22 lb. ft.).





28. Roll pin in offset lever and shift rail.
29. Damper sleeve in offset lever.
- Turn transmission case on end, and mount a dial indicator on extension housing with indicator on the end of mainshaft.





Measure
a. Mainshaft end play.
- Rotate mainshaft and zero dial indicator. Pull upward on mainshaft until end play is removed and record reading.
- Ideal mainshaft end play is zero with plus or minus 0.02 mm (0.001 in.) allowable.
- To set preload, select a shim pack equal to the dial indicator reading recorded.
b. Remove front bearing retainer and front bearing race.
c. Install necessary shims and reinstall bearing race. Refer to "Specifications."
d. Apply a 3 mm (0.125 in.) bead of RTV Sealant GM PIN 12345739 on case mating surface of front bearing retainer.

30. Bearing retainer.
31. Retainer bolts
- Apply pipe thread sealant GM PIN 1052080 to the threads of the retainer bolts.

Tighten
- Retainer bolts to 20 N.m (15 lb. ft.).

32. Drain plug.
- Apply pipe thread sealant GM PIN 1052080 to the threads of the drain and fill plugs.

Tighten
- Drain plug to 27 N.m (20 lb. ft.).

33. Fill the transmission to its proper level with Dextron III
34. Fill plug.

Tighten
- Fill plug to 27 N.m (20 lb. ft.).