Transaxle Assembly
INSTALL OR CONNECT^ Tools Required:
- J 36850 Transjel Transmission Assembly Lubricant
- J 26900-5 Vernier Caliper
- J 34673 Flat Gage Bar
1. Countershaft assembly to input shaft assembly and place high speed and low speed gearshift shafts onto the countershaft and input shaft assemblies.
2. Input shaft assembly, countershaft assembly, high speed and low speed gearshift shafts into the right case simultaneously as a cluster.
Important
- When installing the differential assembly into the right case, rotate the differential assembly so that the speedometer drive gear meshes with the speedometer driven gear.
3. Differential assembly into the right case using a plastic mallet to seat the right differential side bearing.
Important
- When installing the 5th and reverse gearshift guide shaft, make sure the reverse gearshift arm engages with the reverse gearshift lever during installation.
4. 5th and reverse gearshift shaft with 5th and reverse gearshift guide shaft into the right case.
5. Reverse idler gear, washer and shaft making sure the alignment mark on the reverse idler shaft is aligned with the case casting mark on the right case.
6. Gearshift yoke to gearshift arm.
7. Apply RTV silicone sealer equivalent, to the left case GM P/N 1052917, or mating surface.
8. Left case to the right case by placing the left case over the input shaft and countershaft assemblies.
9. Two transaxle case bolts inside the clutch housing of the right case.
Tighten
- Transaxle case bolts to 22 N.m (16 lb. ft.).
10. Eleven transaxle case bolts into the left case.
Tighten
- Transaxle case bolts to 22 N.m (16 lb. ft.).
11. Apply Loctite 414 GM P/N 12345493, or equivalent, to the threaded portion of the reverse idler shaft bolt (Item "A").
12. Reverse idler shaft bolt and washer into the left case.
Tighten
- Reverse idler shaft bolt to 14 N.m (10 lb. ft.).
Important
- When installing the gearshift and select shaft assembly, the transaxle must be in neutral. This will allow the installation of the interlock plate.
13. Gearshift and select shaft assembly into the left case inserting the bottom of the gearshift and select shaft into the gearshift yoke.
14. Gearshift interlock bolt and washer into the left case. Check bolt head for strength identification number.
Tighten
- Gearshift interlock bolt (strength 7) to 23 N.m (17 lb. ft.).
- Gearshift interlock bolt (strength 12) to 34 N.m (25 lb. ft.).
Inspect
- Backup lamp switch O-ring for cuts or other damage. Replace as necessary.
15. Backup lamp switch into left case.
Tighten
- Backup lamp switch to 20 N.m (15 lb. ft.).
16. Apply RTV silicone sealer GM P/N 1052917, or equivalent, to the mating surface of the gearshift guide case.
17. Gearshift guide case and retaining clamp to left case; secure with four bolts.
Tighten
- Gearshift guide case bolts to 10 N.m (89 lb. in.).
Inspect
- Locating springs for distortion or damage and replace as necessary.
Measure
^ Tool Required:
- J 26900-5 Vernier Caliper
- Locating springs using a J 26900-5. Any spring not within its service limit should be replaced.
- Low speed locating spring standard length 26.1 mm (1.028-inch).
Important
- Low speed locating spring service limit 25.0 mm (0.984-inch).
- High speed locating spring standard length 40.1 mm (1.597-inch).
- High speed locating spring service limit 39.0 mm (1.535-inch).
- 5th speed locating spring standard length 26.1 mm (1.028-inch).
- 5th speed locating spring service limit 25.0 mm (0.984-inch).
- Locating springs are color coded for ease of assembly. Make sure each spring is installed in its respective position.
18. Three steel balls, three locating springs and three gearshift shaft screws with washers into the right case.
Tighten
- Gearshift shaft screws to 13 N.m (10 lb. ft.).
19. Apply Loctite (tm) 414 GM P/N 12345493, or equivalent, to the threaded portion of the gearshift yoke bolt.
20. Gearshift yoke bolt to gearshift yoke.
Tighten
- Gearshift yoke bolt to 36 N.m (26 lb. ft.).
21. Left case cap O-ring and left case cap to left case; secure with three bolts.
Tighten
- Left case cap bolts to 10 N.m (89 lb. in.).
Measure
^ Tool Required:
- J 34673 Flat Gage Bar
- Bearing set shim protrusion using a J 34673 and a feeler gage. Place a suitable size bearing set shim on the left Countershaft bearing race and place the J 34673 across the end of the left case. Then, using a feeler gage, measure the clearance between the J 34673 and the left case surface. Bearing set shim clearance should measure within 0.08 to 0.12 mm (0.0032 to 0.0047-inch).
22. Apply Loctite 414 GM P/N 12345493, or equivalent, to the threaded portion of the left case plate screws.
23. Left case plate by placing it over the input shaft and Countershaft while placing the end tab in the groove in the 5th and reverse gearshift guide shaft; secure with six screws.
Tighten
- Left case plate screws to 10 N.m (7 1b. ft.).
Inspect
- Countershaft by hand for smooth rotation after tightening the left case plate screws.
24. Countershaft 5th gear to Countershaft with the machined boss "A" facing inward.
25. Synchronizer ring springs and 5th speed hub to 5th speed sleeve.
Important
- Short side "C" on keys, long boss "D" in hub and chamfered spline "F" in sleeve should face inward toward the input shaft 5th gear.
26. 5th speed gearshift fork to 5th speed sleeve and hub.
27. Apply J 36850 to the input shaft needle bearing.
28. 5th gear bearing, input shaft 5th gear, 5th speed synchronizer ring, synchronizer ring spring, 5th speed sleeve and hub and 5th speed gearshift fork simultaneously onto the input shaft.
Important
- During installation of the 5th speed gearshift fork and 5th speed sleeve and hub onto the input shaft, make sure to align the hub oil groove with the input shaft mark.
29. Gearshift fork roll pin with the split side of the pin facing away from the left case.
30. Apply a light coat of Loctite (tm) 414 GM P/N 12345493, or equivalent, to the threaded portion of the shift fork plug.
31. Gearshift guide ball and gearshift fork plug into the 5th speed gearshift fork.
Tighten
- Gearshift fork plug to 13 N.m (10 lb. ft.).
32. Engage the transaxle by pushing in on the shift shaft.
33. Engage 5th gear by sliding the 5th speed sleeve down. The transaxle is now locked in two gears, preventing input shaft rotation and permitting Countershaft nut installation.
34. Countershaft nut onto the countershaft.
Tighten
- Countershaft nut to 70 N.m (52 lb. ft.).
35. Stake countershaft nut with a standard drift punch and hammer.
36. 5th speed synchronizer hub plate to input shaft; secure with the 5th speed synchronizer retainer.
37. Apply RTV silicone sealer GM P/N 1052914, or equivalent, to the mating surface of the transaxle side cover.
38. Transaxle side cover to the left case; secure with eight bolts.
Tighten
- Transaxle side cover bolts to 6 N.m (53 lb. in.).