Transaxle Case Assembly
^ Tools Required:- J 26540 Input Shaft Seal Installer
- J 8092 Driver Handle
- J 41679 Bearing Race Installer
- J 7817 Bearing Installer
- J 8611-01 Bearing Race Installer
- J 33373 Shim Selector
- J 24256-A Bearing Race Installer
- J 33370 Bearing Race Installer
- J 26938/J 29130 Drive Axle Seal Installer
- J 33374 Bearing Installer
- J 36037 Outer Bushing Installer
- J 37159 Inner Bearing Installer
- J 36190 Driver Handle
- Or Equivalents
NOTICE: Before reassembly, attach the clutch housing to the transaxle holding fixture if removed.
INSTALL OR CONNECT
1. New input shaft seal using J 26540.
Front Input Shaft Roller Bearing:
Front Output Shaft Bearing Race:
Front Differential Bearing Race:
2. Front roller bearing for the input shaft, output shaft and differential into the clutch housing.
NOTICE: Apply oil to the bearing before installation.
^ Using J 41679 with driver handle J 8092, press input bearing into housing.
^ Using J 7817 with a hammer, press output race into housing.
^ Using J 8611-01 with driver handle J 8092, press differential race into housing.
3. Apply grease to three 10 mm interlock pins, and install them on the clutch housing.
4. Reverse shift brackets on the clutch housing. Use 3rd/4th shift shaft to align bracket to housing. Install retaining bolts.
Tighten
Retaining bolts 17 Nm (13 ft. lbs.).
NOTICE: Make sure shaft operates smoothly after installation.
5. Differential case assembly first, then install the input and output shaft with the 3rd/4th shift fork and shaft together as an assembly into the clutch housing. Make sure that the 13 mm lock pin is in the 3rd/4th shifter shaft before installing. The 3rd/4th shift shaft is installed into the raised collar of reverse shift lever bracket.
6. 1st/2nd gear shift fork onto the synchronizer sleeve and insert the shift shaft into the reverse shift lever bracket. Align hole in fork with the shaft and install a new double roll pin.
7. Reverse lever on shift bracket.
8. Install 5th shift shaft (with the reverse-5th shift blocker and 10 mm interlock pin installed). Align 5th shift shaft interlock detent then install reverse shift shaft and snap ring. Make sure 12 mm lock pin is in the 5th gear shifter shaft before installing.
9. Reverse idle shaft together with the gear into the clutch housing. Make sure reverse lever is engaged in collar of gear.
10. Determine shim size.
Measure
A. Position the outer bearing races on the output and differential bearings. Position the shim selection gages on the bearing races as shown. The 2 gages are identified as output and differential.
B. Place seven spacers provided with J 33373 evenly around the perimeter of the clutch housing.
C. Install bearing, snap ring, shim retainer. Apply Loctite 242 GM P/N 12345382, or equivalent to the threads of the seven shim retainer screws and install with Torx(tm) (No. 45) on transaxle case.
Tighten
Shim retainer screws to 23 Nm (17 ft. lbs.).
D. Carefully position the transaxle case over the gages and on the spacers. Install the seven bolts provided with the tool kit.
Tighten
^ Bolts to 13 Nm (10 ft. lbs.)
^ Alternately until case is seated on spacers.
E. Rotate each gage to seat the bearings. Rotate the differential case through three revolutions in each direction.
F. With the two gages compressed, measure the gap between the outer sleeve and the base pad using available shim sizes.
^ The differential should use a shim three sizes larger than that which will smoothly fit in the gap.
^ The output shaft should use the largest shim that can be placed into the gap and drawn through without binding.
G. When the two shims have been selected, remove the transaxle case, seven spacers and three gages.
11. Position the shim selected for the input, output and differential into the bearing race bores in the transaxle case.
12. Rear output shaft bearing race using J 33370 with J 8092.
13. Rear differential case bearing race using J 8611-01 with J 8092 and a press. Apply oil to the bearing race before installation. Press bearing until sealed in its bore.
14. Magnet in clutch housing.
15. Clean the clutch housing and transaxle case mating surfaces, and apply a 1/8" bead of RTV silicone sealer GM P/N 1052917, or equivalent to the mating surfaces. Be sure magnet is installed in the clutch housing.
16. Transaxle case on the clutch housing. Install the snap ring into the ball bearing groove. Install the reverse idle shaft bolt into the transaxle case.
Tighten
Reverse idle shaft bolt to 38 Nm (28 ft. lbs.).
17. Fourteen case bolts.
Tighten
Case bolts to 38 Nm (28 ft. lbs.) in a diagonal sequence.
18. Drive axle seals using J 26938 or J 29130 with J 8092.
19. Thrust washer and collar to the output shaft using J 33374. Before installing, apply oil to the thrust surfaces and collar.
20. Fifth gear to the input shaft. Install the needle bearing, 5th gear, blocker ring, hub/sleeve assembly with shift fork in its groove and back plate on the output shaft. Align shift fork on shift shaft and install a new double roll pin. Before installing, apply oil to the output gear thrust surfaces.
21. Detent balls and detent springs for the reverse lst/2nd, 3rd/4th and 5th speeds. Install retaining bolts.
Tighten
Retaining bolt 25 Nm (18 ft. lbs.).
22. Carefully wipe any oil from the threads on the input and output shafts. Apply loctite(tm) 414 GM P/N 12345093, or equivalent to the threads of the input and output shafts. Use care not to allow the material not to flow into the splines of the 5th gear and input shaft. Install new retaining nuts.
Tighten
Retaining nuts 128 Nm (94 ft. lbs.).
Stake nuts after tightening.
23. Assemble the control box as follows:
^ Assemble the stopper cam and the internal lever. Make sure that the splines on the stopper cam and the internal lever are aligned.
^ Install the stopper cam and internal lever to the shift lever assembly.
^ Align the stopper cam alignment mark with the center on the internal lever.
^ Check to see that the reverse inhibitor mechanism operates properly.
^ Use a new roll pin to attach the internal lever during assembly.
24. Clean the control box and transaxle case mating surfaces, apply a 1/8 inch bead of RTV silicone sealer GM P/N 7052917. or equivalent to the mating surface. Install four bolts
Tighten
Bolts to 17 Nm (13 ft. lbs.).
NOTICE: Make sure the transaxle shifts properly before installing the rear cover bolts.
25. New gasket with the rear cover and rear cover bolts.
Tighten
Bolts to 17 Nm (13 ft. lbs.).
Measure
Rotating torque on the input shaft as shown. When measuring, the input shaft should be to the upper side and the differential assembly to the lower side. The rotating torque should be less than 7 inch lbs.