1. Transmission Disassemble
Transmission Disassemble (GTO)Extension Housing Removal
^ Tools Required
- J 3289-20 Holding Fixture Bench Mount
- J 39430 Transmission Support Fixture
- J 39431-1 Gear Remover and Bolts
- J 8433 Universal Bridge Puller
- J 41099 Solenoid Socket
1. Remove the vent pipe.
2. Install the J 39430.
3. Mount the transmission on a workbench using the J 3289-20.
4. Rotate the transmission into a horizontal position.
5. Remove the transmission drain plug and drain the transmission fluid.
6. Shift the transmission into neutral (N).
7. Remove the shifter boot.
8. Remove the shift lever cover screws.
9. Remove the shift lever cover.
10. Remove the shifter bolts.
11. Remove the shifter and shifter gasket.
12. Remove rear offset shift lever roll pin.
13. Remove rear offset shift lever and isolator cup.
14. Remove the reverse lockout solenoid from the reverse lockout body using J 41099.
15. Remove the reverse lockout assembly bolt and reverse lockout body.
16. Remove the speed sensor bolt and the speed sensor.
17. Remove the rear extension housing bolts and the rear extension housing.
18. Remove the speed sensor reluctor wheel retaining ring.
19. Remove the speed sensor reluctor wheel using J 39431-1 and J 8433.
20. Remove the speed sensor reluctor wheel retaining ring.
Reverse Speed Gear Removal
1. Remove the rear bearing retainer ring.
2. Remove the spacer.
3. Remove the mainshaft rear roller bearing.
4. Remove the spacer.
5. Remove the retainer ring.
6. Remove the reverse gear thrust washer.
7. Remove the reverse gear.
8. Remove the reverse gear caged needle bearing.
9. Remove the wave washer.
10. Remove the reverse gear synchronizer blocking ring.
Reverse Shift Fork Removal
1. Remove the reverse synchronizer retainer ring.
2. Remove the reverse shift fork retainer ring. Discard the retainer ring.
3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.
4. Remove the following parts in order:
4.1. The thrust washer
4.2. The reverse synchronizer assembly and the shift fork
5th/6th Speed Driven Gear Removal
^ Tools Required
- J 8433 Universal Bridge Puller
- J 39431-1 Gear Remover
Remove the 5th/6th speed driven gear, using the J8433 and the J39431-1.
Countershaft Extension Removal
1. Remove the 5th/6th speed shift fork retainer ring.
2. Rotate the transmission in the horizontal position with the guide plate up.
3. Remove the countershaft extension assembly with the 5th/6th speed shift fork.
Transmission Case Removal
^ Tools Required
- J 41099 Reverse Solenoid Socket
1. Remove the computer aided gear select solenoid.
2. Remove the shifter cover plate retainer bolts.
3. Remove the shifter cover plate.
4. Remove the shift detent assembly.
5. Remove 9 of the 11 adapter plate to transmission case bolts.
6. Rotate the transmission into the vertical position.
7. Remove the last 2 adapter plate to transmission case bolts.
8. Remove the shift lever guide bolts.
9. Remove the magnets from the transmission case.
10. Remove the offset lever roll pin.
11. Remove the transmission case and the offset lever together as follows:
11.1. Slide the transmission case up and off of the gear clusters and the shift shaft components.
11.2. Hold the offset lever against the guide plate in order to prevent the release of the detent ball and the spring.
11.3. Remove the offset lever from the transmission case.
Guide Plate Removal
1. Remove the detent guide plate attaching bolts.
2. Remove the detent guide plate.
Reverse Lockout Assembly Disassemble
Caution: The reverse lockout assembly is under spring pressure. Exercise caution when removing the retainer ring, as bodily injury may result.
1. Disassemble the reverse lockout assembly in the following sequence:
2. Remove the O-ring (8) from the body (1).
3. Remove the retainer ring (7) from the body (1).
4. Remove the reverse lockout inner spring (2).
5. Compress the reverse lockout plunger (6) and the collar (4) in a vise and remove the retainer ring (3).
6. Remove the reverse lockout plunger (6).
7. Remove the reverse lockout outer spring (5).
8. Remove the reverse lockout collar (4).
Shift Shaft Assemblies and Gear Cluster Removal
1. Rotate the 5th/6th and the reverse shift shaft levers off the shift interlock plate.
2. Remove the 5th/6th and the reverse shift shaft assembly.
3. Remove the countershaft. Lift up the mainshaft enough in order to remove the countershaft.
4. Remove the mainshaft and the shift shaft components as an assembly.
5. Remove the shift shaft assembly from the mainshaft.
6. Remove the 4th speed gear blocker ring.
7. Remove the input shaft.