Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

J 37758 Countershaft Rear Plug Installer. See Special Tools and Equipment .
J 8092 Driver Handle. See Special Tools and Equipment .
J 36850 Transjel Transmission Assembly Lubricant. See Special Tools and Equipment .
J 8614-01 Countershaft Driven Gear Holder. See Special Tools and Equipment .
J 34826 Hub Nut Socket. See Special Tools and Equipment .
J 35552 Differential Side Bearing Cup Installer. See Special Tools and Equipment .

Install the countershaft drive gear outer race (2) into the transaxle case (1) using a J 37758 with a J 8092 and a hydraulic press.

Fig 1: Installing Countershaft Drive Gear Outer Race
Courtesy of GENERAL MOTORS CORP.
Install the countershaft drive gear outer race snap ring (1) onto the countershaft drive gear outer race (2).

Fig 2: Installing Countershaft Drive Gear Outer Race Snap Ring
Courtesy of GENERAL MOTORS CORP.
Install the new crush sleeve onto the countershaft drive gear.
Apply J 36850 to the countershaft drive gear and outer bearings.
Install the countershaft drive gear into the transaxle case using a J 35552 with a J 8092 and a hydraulic press.
Install the countershaft drive gear inner bearing into the countershaft drive gear outer race.
Install the intermediate shaft (2) into the transaxle case (1) and into the countershaft drive gear.

Fig 3: Installing Intermediate Shaft
Courtesy of GENERAL MOTORS CORP.
Install a J 8614-01 onto the countershaft driven gear stationary during intermediate shaft locknut installation.
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Install the intermediate shaft locknut onto the intermediate shaft using a J 34826 .
Tighten
1. Tighten the intermediate shaft locknut to 177 N.m (131 lb ft).
Remove the J 8614-01 from the countershaft driven gear.
Stake the intermediate shaft locknut.
Inspect the intermediate shaft (1) for smooth rotation.

Fig 4: Checking Intermediate Shaft Rotation
Courtesy of GENERAL MOTORS CORP.
If the intermediates shaft does not rotate smoothly, remove the countershaft drive gear bearings and inspect for excessive wear or damage.
Clean the sealant from the rear case cover mating surfaces on the rear case cover and transaxle case (2).
Apply the RTV silicone sealer GM P/N 1052917, or equivalent, to the rear case cover mating surface.
Important: Eleven of the 13 rear case cover bolts are 25 mm (0.984 in) in length. The two remaining bolts are 32 mm (1.259 in) in length. Verify that the two longer bolts are installed in their correct position.
Install the rear case cover (1) to the transaxle case. Secure the assembly with 13 bolts.
Tighten
1. Tighten the rear case bolts to 10 N.m (89 lb in).
Fig 5: Identifying Rear Case Bolts
Courtesy of GENERAL MOTORS CORP.