Transmission Disassemble

Tools Required

• J 23907  Slide Hammer
• J 36509  Detent Spring Plug Remover. See Special Tools .
• J 36511  Oil Fill and Drain Plug Hex Bit - 17 mm. See Special Tools .
• J 36515  Assembly Pallet. See Special Tools .
• J 36515-15  Mainshaft Adapter. See Special Tools .
• J 36515-16  Countershaft Adapter. See Special Tools .
• J 36825  Output Shaft Oil Seal Remover

IMPORTANT: The transmission must remain in 3rd or 5th gear in order to prevent losing the shift shaft lever spring and plunger.
Fig 1: Removing Oil Fill Plug
Courtesy of GENERAL MOTORS CORP.
1. Using the J 36511  , remove the oil fill plug. See Special Tools .
2. If the transmission is not in 3rd or 5th gear, reinstall the shift control housing and shift the transmission in 3rd or 5th gear.
3. Place a suitable container under the transmission assembly in order to drain the remaining transmission fluid.
4. Using J 36511  , remove the oil drain plug. See Special Tools .
   Fig 2: Removing Oil Drain Plug

   Courtesy of GENERAL MOTORS CORP.
5. Remove the gasket material from the housing.
6. Remove the 2 reverse idler gear shaft support bolts.
   Fig 3: Removing Reverse Idler Gear Shaft Support Bolts

   Courtesy of GENERAL MOTORS CORP.
7. Remove the back-up lamp switch.
   Fig 4: Removing Back-Up Lamp Switch

   Courtesy of GENERAL MOTORS CORP.
8. If 2WD, remove the vehicle speed sensor and O-ring.
   Fig 5: Removing Vehicle Speed Sensor

   Courtesy of GENERAL MOTORS CORP.
9. Remove the shift shaft detent pin.
   Fig 6: Removing Shift Shaft Detent Pin

   Courtesy of GENERAL MOTORS CORP.
10. Using the J 36509  (1) and the J 23907  (2), remove the detent plug, spring, and detent plunger.
    Fig 7: Removing Detent Plug, Spring & Plunger

    Courtesy of GENERAL MOTORS CORP.
11. If 4WD vehicle, remove the output shaft seal using the J 36825  and the J 23907  . Screw the J 36825  into 1 of the 3 perforated holes in the seal.
    Fig 8: Removing Output Shaft Seal

    Courtesy of GENERAL MOTORS CORP.
12. Remove the 6 bolts securing the input shaft bearing retainer to the clutch housing.
    Fig 9: Removing Input Shaft Bearing Retainer Bolts

    Courtesy of GENERAL MOTORS CORP.

    Remove the retainer by screwing 2 of the removed bolts into the threaded holes in the retainer.

13. Remove the input shaft bearing retainer ring.
    Fig 10: Removing Input Shaft Bearing Retainer Ring

    Courtesy of GENERAL MOTORS CORP.
14. Remove the bolts securing the clutch housing to the rear case.
    Fig 11: Removing Clutch Housing-To-Rear Case Bolts

    Courtesy of GENERAL MOTORS CORP.
NOTE: Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.
Fig 12: Removing Clutch Housing
Courtesy of GENERAL MOTORS CORP.
15. Separate the clutch housing from the rear case using a soft-face hammer. Do not pry at the sealing surfaces.
16. Remove the countershaft front bearing.
    Fig 13: Removing Countershaft Front Bearing

    Courtesy of GENERAL MOTORS CORP.
17. Move the reverse idler gear shaft towards the countershaft.
18. Remove the reverse idler gear shaft support.
    Fig 14: Removing Reverse Idler Gear Shaft Support

    Courtesy of GENERAL MOTORS CORP.
IMPORTANT: If the shift rail is rotated, the shift lever spring and plunger may come out of the shift shaft lever.
19. Slowly shift the transmission in neutral.
20. Rotate the shift rail counterclockwise. While rotating, catch the shift shaft plunger and the shift shaft spring.
    Fig 15: Removing Shift Lever Spring & Plunger

    Courtesy of GENERAL MOTORS CORP.
21. Remove the shift shaft lever roll pin.
    Fig 16: Removing Shift Shaft Lever Roll Pin

    Courtesy of GENERAL MOTORS CORP.
    1. Rotate the shift shaft lever finger down.
    2. Support the shift shaft end.
    3. Drive out the roll pin.
    4. Ensure that the roll pin clears the 2nd speed gear.
22. Remove the shift shaft socket roll pin.
    1. Align the shift shaft socket in the center of the case opening.
    2. Using a 5 mm (3/16 in) punch, remove the roll pin.
    Fig 17: Removing Shift Shaft Socket Roll Pin

    Courtesy of GENERAL MOTORS CORP.
23. Remove the following components:
    1. The shift shaft
    2. The shift shaft socket
    3. The shift shaft lever
    4. The shift shaft block out bushing
    Fig 18: Removing Shift Shaft & Components

    Courtesy of GENERAL MOTORS CORP.
24. Rotate the 3rd/4th speed gear shift fork counterclockwise.
25. Remove the 3rd/4th speed gear shift fork from the transmission case.
    Fig 19: Removing 3rd/4th Gear Shift Fork

    Courtesy of GENERAL MOTORS CORP.
26. If 2WD vehicle, loosen the 3 bolts on the rear of the housing. Do not remove the bolts.
    Fig 20: Loosening Rear Housing Bolts (2WD)

    Courtesy of GENERAL MOTORS CORP.
27. Install the J 36515-15  (3) on the input shaft. See Special Tools .
    Fig 21: Identifying J 36515, J 36515-15, & J 36515-16

    Courtesy of GENERAL MOTORS CORP.
28. Install the J 36515-16  (1) on the countershaft. See Special Tools .
29. Install the transmission to the J 36515  (2). See Special Tools .
30. Adjust the reverse holding pin against the reverse gear idler shaft.
31. If 2WD vehicle, remove the 3 bolts on the rear of the housing.
    Fig 22: Removing 3 Bolts On Rear Of Housing (2WD)

    Courtesy of GENERAL MOTORS CORP.
32. If 4WD vehicle, remove the main shaft rear bearing retaining ring.
    Fig 23: Removing Main Shaft Rear Bearing Retaining Ring (4WD)

    Courtesy of GENERAL MOTORS CORP.
33. Remove the rear housing, 4WD shown. Tap the rear housing with a rubber mallet.
    Fig 24: Removing Rear Housing

    Courtesy of GENERAL MOTORS CORP.