10. Transaxle Assemble

^ Tools Required
^ J 36850 Transjel Transmission Assembly Lubricant
^ J 26900-5 Vernier Clamp
^ J 34673 Flat Gage Bar





1. Connect the countershaft assembly to the input shaft assembly.
2. Install the high and low speed gearshift shafts onto the countershaft and the input shaft assemblies.
3. Install the input shaft assembly, the countershaft assembly and the 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.

4. Install the differential assembly into the right case. Use a plastic mallet in order to seat the right differential side bearing.





Important: When installing the 5th and reverse gearshift guide shaft, make sure that the reverse gearshift arm engages with the reverse gearshift lever during installation.

5. Install the 5th and reverse gearshift shaft with the 5th and reverse gearshift guide shaft into the right case.





6. Install the reverse idler gear, the washer and the shaft. Make sure that the alignment mark on the reverse idler shaft is aligned with the casting mark on the right case.
7. Connect the gearshift yoke to the gearshift arm.
8. Apply the RTV silicone sealer GM P/N 1052917, or equivalent, to the left case mating surface.
9. Install the left case to the right case by placing the left case over the input shaft and the countershaft assemblies.
10. Install the two transaxle case bolts inside the clutch housing of the right case.
^ Tighten the bolts to 22 Nm (16 ft. lbs.).

Notice: Refer to Fastener Notice in Service Precautions.





11. Install the eleven transaxle case bolts (1) into the left case.
^ Tighten the transaxle case bolts (1) to 22 Nm (16 ft. lbs.).





12. Apply Loctite(r) 414 GM P/N 12345493 or equivalent to the threaded portion of the reverse idler shaft bolt.





13. Install the reverse idler shaft bolt (2) and the washer into the left case.
^ Tighten the bolt to 14 Nm (10 ft. lbs.).





Important: When installing the gearshift and select shaft assembly, the transaxle must be in (N) Neutral. This will allow the installation of the interlock plate.

14. Install the gearshift and select shaft assembly into the left case. Insert the bottom of the gearshift and select shaft into the gearshift yoke.





15. Install the gearshift interlock bolt and washer into the left case. Check the bolt head for the strength identification number.
^ Tighten the gearshift interlock bolt (strength 7) to 23 Nm (17 ft. lbs.).
^ Tighten the gearshift interlock bolt (strength 12) to 34 Nm (25 ft. lbs.).
16. Inspect the backup lamp switch O-ring for cuts or other damage. Replace as necessary.
17. Install the backup lamp switch into the left case.
^ Tighten the backup lamp switch to 20 Nm (15 ft. lbs.).





18. Apply RTV silicone sealer GM P/N 1052917, or equivalent, to the mating surface of the gearshift guide case.
19. Connect the gearshift guide case and retaining clamp to the left case. Secure with the four gearshift guide case bolts.
^ Tighten the gearshift guide case bolts to 10 Nm (89 inch lbs.).

Important: The locating springs are color coded for ease of assembly. Install each spring correctly according to the color code.

20. Inspect the locating springs for distortion or damage. Replace as necessary.





21. Use a J 26900-5 in order to measure the locating springs. Replace any spring not within its service limit.
^ The Low speed locating spring standard length is 26.1 mm (1.028 inch).
^ The Low speed locating spring service limit is 25.0 mm (0.984 inch).
^ The High speed locating spring standard length is 40.1 mm (1.597 inch).
^ The High speed locating spring service limit is 39.0 mm (1.535 inch).
^ The 5th speed locating spring standard length is 26.1 mm (1.028 inch).
^ The 5th speed locating spring service limit is 25.0 mm (0.984 inch).





22. Install the three steel balls, the three locating springs and the three gearshift shaft screws with washers into the right case.
^ Tighten the gearshift shaft screws to 13 Nm (10 ft. lbs.).
23. Apply Loctite(r) 414 GM P/N 12345493 or equivalent to the threaded portion of the gearshift yoke bolt.





24. Connect the gearshift yoke bolt to the gearshift yoke.
^ Tighten the gearshift yoke bolt to 36 Nm (26 ft. lbs.).
25. Install the left case cap O-ring and the left case cap to the left case. Secure with the three bolts.
^ Tighten the left case bolts to 10 Nm (89 inch lbs.).





26. Measure the bearing set shim protrusion using a J 34673 and a feeler gage.
27. 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.
27.1. Use a feeler gage in order to measure the clearance between the J 34673 and the left case surface.
27.2. The bearing set shim clearance should measure within 0.08 to 0.12 mm (0.0032 to 0.0047 inch).





28. Apply Loctite(r) 414 GM P/N 12345493 or equivalent to the threaded portion of the left case plate screws.
29. Install the 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 the six screws.
^ Tighten the left case plate screws to 10 Nm (7 ft. lbs.).
30. After tightening the left case plate screws, inspect the countershaft by hand for smooth rotation.





31. Install the countershaft 5th gear to the countershaft with the machined boss facing inward.





Important: The short side (1) on the keys, the long boss (2) in the hub and the chamfered spline (3) in the sleeve should face inward toward the input shaft 5th gear.

32. Install the synchronizer ring springs and the 5th speed hub to the 5th speed sleeve.





33. Connect the 5th speed gearshift fork to the 5th gear sleeve and hub.
34. Apply the J 36850 to the input shaft needle bearing.

Important: During installation of the 5th speed gearshift fork and the 5th speed sleeve and hub onto the input shaft, make sure to align the hub oil groove (2) with the input shaft mark (1).

35. Install the 5th gear bearing, the input shaft 5th gear, the 5th speed synchronizer ring, synchronizer ring spring, the 5th speed sleeve and hub and the 5th speed gearshift fork onto the input shaft simultaneously.





36. Install the gearshift fork roll pin (1) with the split side of the pin facing away from the left case.
37. Apply a light coat of Loctite(r) 414 GM P/N 12345493 or equivalent to the threaded portion of the shift fork plug.
38. Install the gearshift guide ball and the gear shift fork plug into the 5th speed gearshift fork.
^ Tighten the gearshift fork plug to 13 Nm (10 ft. lbs.).
39. Engage the transaxle by pushing in on the shift shaft.
40. Engage the 5th gear by sliding the 5th speed sleeve down. The transaxle is now locked in two gears. This prevents rotation of the input shaft and permits installation of the countershaft nut
41. Install the countershaft nut onto the countershaft.
^ Tighten the countershaft nut to 70 Nm (52 ft. lbs.).
42. Stake the countershaft nut with a standard drift punch and a hammer.





43. Install the 5th speed synchronizer hub plate onto the input shaft. Secure with the 5th speed synchronizer retainer (2).





44. Apply RTV silicone sealer GM P/N 1052914 or equivalent to the mating surface of the transaxle side cover.
45. Connect the transaxle side cover to the left case. Secure the side cover with the eight transaxle side cover bolts.
^ Tighten the transaxle side cover bolts to 6 Nm (53 ft. lbs.).