Transaxle Case Assembly

Tools Required

• J 7079-2  Universal Driver Handle - Non-Threaded. See Special Tools .
• J 8092  Universal Driver Handle - 3/4 in - 10
• J 44375 Assembly Pallet
• J 44376 Bearing Pusher/Puller
• J 44377 Input Shaft Anti-Rotation Tool
• J 44381 Shifter Bearing/Input and Output Bearing Remover
• J 44383 Countershaft Bearing Installer (to case)
• J 44385  Differential Bearing Race and Seal Installer. See Special Tools .
• J 44387 Output Shaft Bearing Sleeve Installer and Pin
• J 44389 Countershaft Bearing Installer

Fig 1: Shift Rod, Bushing & Transmission Housing
Courtesy of GENERAL MOTORS CORP.
1. Install the shift rod and bushing.
Fig 2: Intermediate Shaft Needle Bearing
Courtesy of GENERAL MOTORS CORP.
2. Install the intermediate shaft needle bearing to the transmission housing using the J 44383 (1) and the J 8092  (2).
Fig 3: Identifying J 44381 & J 7079-2
Courtesy of GENERAL MOTORS CORP.
3. Install a new shifter shaft bearing flush with the casting in the transmission housing, using the J 44381 (1) and the J 8092  (2).
Fig 4: Bolt, Lever, Spring & Transmission Housing
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Do not over apply the threadlocker to the bolt threads.
4. Apply P/N 21485277 to the reverse lockout lever bolt threads.
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
IMPORTANT: The spring (2) fingers must be positioned on either side of the lever (3).
5. Install the reverse lockout lever (3), spring (2), and the bolt (1) to the transmission housing, if equipped.

   Tighten:  Tighten the bolt to 6 N.m (53 lb in).

Fig 5: Differential Bearing Race, J 44381 & J 7079-2
Courtesy of GENERAL MOTORS CORP.
6. Install a new differential bearing race to the transmission housing using the J 44385  (2) and the J 7079-2  (1). See Special Tools .
Fig 6: Axle Seal, J 44385 & J 7079-2
Courtesy of GENERAL MOTORS CORP.
7. Install a new differential side bearing race seal to the transmission housing using the J 44385  (2) and the J 7079-2  (1). See Special Tools .
Fig 7: Countershaft Bearing, J 44381 & J 7079-2
Courtesy of GENERAL MOTORS CORP.
8. Install the countershaft bearing to the clutch housing using the J 44381 (1) and the J 7079-2  (2). See Special Tools .
9. Install a new snap ring.
Fig 8: Input Shaft Bearing, J 44381 & J 7079-2
Courtesy of GENERAL MOTORS CORP.
10. Install the input shaft bearing to the clutch housing using the J 44381 (2) and the J 7079-2  (1). See Special Tools .
Fig 9: Output Shaft Bearing Race
Courtesy of GENERAL MOTORS CORP.
11. Install the output shaft bearing race and bolts using the J 44387-1 (2), J 44387-2 (3), and the J 7079-2  (1). See Special Tools .

    Tighten:  Tighten the output shaft bearing bolts to 10 N.m (89 lb in).

Fig 10: Differential Bearing Race, Clutch Housing, J 44381 & J 7079-2
Courtesy of GENERAL MOTORS CORP.
12. Install a new differential bearing race to the clutch housing using the J 44385  (2) and the J 7079-2  (1). See Special Tools .
Fig 11: Shifter Detent
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: If either the case or shifter detent is damaged, it may be necessary to install a new shifter detent and/or case.
13. Install the shifter detent into the case if necessary.
Fig 12: Differential Output Shaft Seal, Clutch Housing, J 44385 & J 8092
Courtesy of GENERAL MOTORS CORP.
14. Install a new differential output shaft seal to the clutch housing using the J 44385  (2) and the J 8092  (1). See Special Tools .
Fig 13: Input/Output Shaft Bearings, Transmission Housing, J 44385 & J 7079-2
Courtesy of GENERAL MOTORS CORP.
15. Install the snap rings to the input shaft and output shaft bearings.
16. Install the input shaft and output shaft bearings into the transmission housing using the J 44385  (2) and the J 7079-2  (1). See Special Tools .
Fig 14: Shift Forks & Gear Assemblies
Courtesy of GENERAL MOTORS CORP.
17. Install the shift forks and the input shaft and output shaft onto the J 44375 .
Fig 15: Intermediate Shaft, Shift Fork & J 44375
Courtesy of GENERAL MOTORS CORP.
18. Install the countershaft and the shift fork onto the J 44375 .
19. Rotate the shaft to verify all gears are properly meshing.
Fig 16: Housing, Shift Forks, Shafts & J 44375
Courtesy of GENERAL MOTORS CORP.
20. Install the housing onto the shift forks and the shafts on to the J 44375 . Line up the shift forks and the shafts with the housing.
Fig 17: Transaxle Case
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Install the transaxle case to the shafts evenly using the J 44376 .
21. Install the transaxle case to the shafts using the J 44376 .
Fig 18: Shaft Bolts & Transmission
Courtesy of GENERAL MOTORS CORP.
22. Shift the transmission into 4th and 5th gear using a screwdriver in an upward direction.
23. Apply P/N 21005994 to the input and output shaft bolts.
24. Install NEW input and output shaft bolts while holding the transmission into 4th and 5th gear in an upward direction.

    Tighten:  Tighten the shaft bolts to 95 N.m (68 lb ft).

Fig 19: Installing Sealant To Rear Cover
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: If shimming is required, refer to Shimming Procedures  before installing the cover.
25. Install sealant P/N 21019581 to the rear cover.
Fig 20: View Of Rear Cover
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The oil guide only installs in one direction. Ensure the oil guide is completely seated in the gear shafts.
26. Install the oil guide.
27. Install the rear cover.
28. Install the rear cover bolt.

    Tighten:  Tighten the rear cover bolt to 23 N.m (17 lb ft).

Fig 21: Backup Lamp Switch
Courtesy of GENERAL MOTORS CORP.
29. Apply sealant P/N 21019581 to the backup lamp switch.
30. Install the backup lamp switch into the transaxle case.

    Tighten:  Tighten the backup lamp switch to 18 N.m (13 lb ft).

Fig 22: Gear Shafts, Shift Forks & J 44375
Courtesy of GENERAL MOTORS CORP.
31. Turn the transaxle case and the J 44375 over on the table.
32. Remove the J 44375 from the gear shafts and the shift forks.
Fig 23: Oil Tube & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
33. Install the oil tube into the transaxle case.
Fig 24: Shift Rod & Shift Fork
Courtesy of GENERAL MOTORS CORP.
34. Install the shift rod to the shift fork.
Fig 25: Applying Sealer To Transaxle Case-To-Shifter Cover Mating Surface
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Use only the approved sealer for the transaxle case to shifter cover mating surface.
35. Apply sealer P/N 12378516 to the transaxle case to shifter cover mating surface.
Fig 26: View Of Shifter And Retaining Bolts
Courtesy of GENERAL MOTORS CORP.
36. Install the shifter and the shifter retaining bolts.

    Tighten:  Tighten the shifter retaining bolts to 25 N.m (18 lb ft).

    Install all possible shifter bolts with the shifter in the neutral position. Install the last shifter bolt in gear and then shift the transmission back into neutral.

Fig 27: View Of Shifter Guide Bolt
Courtesy of GENERAL MOTORS CORP.
37. Shift the transmission into neutral.
38. Apply P/N 21485278 to the shifter guide bolt.
NOTE: Hand start and tighten the shifter guide bolt to avoid damaging the shift lever.
39. Install the shifter guide bolt.

    Tighten:  Tighten the shifter guide bolt to 25 N.m (18 lb ft).

Fig 28: Differential & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
40. Install the differential into the transaxle case.
Fig 29: Roller Bearing & Output Shaft
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The step in the roller bearing faces opposite of the pinion gear.
41. Install the roller bearing onto the output shaft.
Fig 30: Magnet & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
42. Install the magnet into the transaxle case.
Fig 31: Applying Sealant To Transaxle Case & Clutch Housing Mating Surface
Courtesy of GENERAL MOTORS CORP.
43. Apply sealant P/N 12378516 to the transaxle case to clutch housing mating surface.
Fig 32: Clutch Housing & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
44. Install the clutch housing to the transaxle case.
Fig 33: Countershaft, Clutch Housing Bearing & J 44389
Courtesy of GENERAL MOTORS CORP.
45. Install the countershaft into the clutch housing bearing using the J 44389 .
Fig 34: Transmission Housing Bolts
Courtesy of GENERAL MOTORS CORP.
46. Install the clutch housing to transaxle case bolts.

    Tighten:  Tighten the housing bolts to 27 N.m (20 lb ft).

Fig 35: Transaxle Case Side & Bolts
Courtesy of GENERAL MOTORS CORP.
47. Turn the transmission over.
48. Install the transaxle case to clutch housing bolts.

    Tighten:  Tighten the housing bolts to 27 N.m (20 lb ft).

Fig 36: Locating Shifter
Courtesy of GENERAL MOTORS CORP.
49. Turn the transmission so the shifter is on top.
50. Shift the transmission into any gear.
Fig 37: Actuator & Tube Bolts
Courtesy of GENERAL MOTORS CORP.
51. Install the actuator and tube.
52. Install the actuator and tube bolts.

    Tighten:  Tighten the tube bolts to 10 N.m (89 lb in).

Fig 38: Transmission Drain Plug
Courtesy of GENERAL MOTORS CORP.
53. Apply P/N 21485278 to the transmission drain plug.
54. Install the transmission drain plug.

    Tighten:  Tighten the transmission drain plug to 38 N.m (28 lb ft).

Fig 39: Transmission Filler Cap
Courtesy of GENERAL MOTORS CORP.
55. Install the transmission fill cap.
Fig 40: Intermediate Shaft, Input Shaft, J 44377 & Bolt
Courtesy of GENERAL MOTORS CORP.
56. Hold the input shaft with the J 44377 .
57. Apply P/N 21005994 to the intermediate shaft bolt.
58. Install the bolt in the intermediate shaft.

    Tighten:  Tighten the intermediate shaft bolts to 95 N.m (70 lb ft).

Fig 41: Identifying Plastic Oil Guide
Courtesy of GENERAL MOTORS CORP.
59. Install a new plastic oil guide into the intermediate shaft.
Fig 42: Identifying Intermediate Shaft Seal
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Ensure not to press the sealing cap past the bottom of the chamfer.
60. Install a new intermediate shaft sealing cap.
Fig 43: View Of Vehicle Speed Sensor & Bolt
Courtesy of GENERAL MOTORS CORP.
61. Apply P/N 21485277 to the vehicle speed sensor bolt.
62. Install the vehicle speed sensor, seal, and bolt.

    Tighten:  Tighten the bolt to 12 N.m (106 lb in).

Fig 44: Shift Cable Bracket, Spacers, Isolators & Bolt
Courtesy of GENERAL MOTORS CORP.
63. Install the shift cable bracket (4), the isolators (3), the spacers (2) and the bolt (1).

    Tighten:  Tighten the shift cable bracket bolt to 20 N.m (15 lb ft).