Transmission Assemble

Tools Required

• J 8001  Dial Indicator Set
• J 8092  Universal Driver Handle
• J 8614-01  Flange and Pulley Holding Tool
• J 22828  Input and Countershaft Race Installer
• J 25070  Heat Gun - 500-750F
• J 26900-13  Magnetic Indicator Base
• J 38805  Output Shaft Nut Socket. See Special Tools .
• J 38856  Bearing Cup and Retainer Installer. See Special Tools .

1. Install the following parts:
   1. The overdrive speed gear shift lever
   2. The shift lever shaft

      The notches that retain the overdrive speed gear shift fork are to the outside of the case.

   3. The shift lever retaining pin
   Fig 1: Installing Overdrive Gear Shift Lever

   Courtesy of GENERAL MOTORS CORP.
2. Install a rubber band, in order to hold the overdrive speed gear shift lever back out of the way.
   Fig 2: Holding Overdrive Speed Gear Shift Lever Back With Rubber Band

   Courtesy of GENERAL MOTORS CORP.
3. Using the J 38856  , install the countershaft front bearing cup. See Special Tools .
   Fig 3: Installing Countershaft Front Bearing Cup

   Courtesy of GENERAL MOTORS CORP.
4. Install the countershaft assembly into the transmission case. Position the rear of the countershaft into the rear countershaft bearing bore, then move the front of the countershaft into position.
   Fig 4: Installing Countershaft

   Courtesy of GENERAL MOTORS CORP.
5. Install the countershaft rear bearing, using the following procedure:
   Fig 5: Installing Countershaft Rear Bearing

   Courtesy of GENERAL MOTORS CORP.
   1. Position the transmission case with the front of the case down.
   2. Lift the countershaft, and place a block of wood between the front of the countershaft and the transmission case.
   3. Using the J 22828  , install the countershaft rear bearing.
6. Install the following parts:
   Fig 6: Installing Reverse Idler Gear & Shaft

   Courtesy of GENERAL MOTORS CORP.
   1. The reverse idler gear
   2. The bearing
   3. The washers
   4. The reverse idler gear shaft

      The step on the shaft aligns toward the countershaft, and is installed flush to the case.

7. Position the transmission with the front of the case down.
8. Position the countershaft in the countershaft front bearing cup.
9. Install the countershaft rear bearing cup.
NOTE: Refer to Fastener Notice .
Fig 7: Installing Countershaft Bearing Retainer
Courtesy of GENERAL MOTORS CORP.
10. Temporarily install the countershaft bearing retainer and the bolts.

    Tighten:  Tighten the countershaft bearing retainer bolts to 35 N.m (26 lb ft).

11. Measure the countershaft end play. Use the following procedure:
    Fig 8: Measuring Countershaft End Play

    Courtesy of GENERAL MOTORS CORP.
    1. Using J 26900-13  (2), set the J 8001  (1) on the end of the countershaft.
    2. Zero out the J 8001  .
    3. Using a screwdriver, or the equivalent, lift the countershaft and record the measurement.

       The countershaft end play should be 0.05-0.15 mm (0.002-0.006 in).

    4. Remove the countershaft rear bearing retainer and bolts.
    5. Add shim(s) under the bearing retainer to achieve the correct end play.
12. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) or the equivalent to the countershaft retainer bolts.
13. Install the countershaft bearing retainer and bolts.
    Fig 9: Installing Countershaft Bearing Retainer

    Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the countershaft bearing retainer bolts to 35 N.m (26 lb ft).

14. Using the J 38856  with the J 8092  , install a NEW front countershaft bearing cap. When properly installed, the outer lip of the cap will be flush with case.
    Fig 10: Installing Front Countershaft Bearing Cap

    Courtesy of GENERAL MOTORS CORP.
15. Install the mainshaft assembly into the transmission case.
    Fig 11: Installing Mainshaft Assembly

    Courtesy of GENERAL MOTORS CORP.
16. Lubricate the main drive gear bearing with transmission fluid.
17. Install the main drive gear bearing and the input shaft into the transmission case.
    Fig 12: Installing Input Shaft & Main Drive Gear Bearing

    Courtesy of GENERAL MOTORS CORP.
18. Apply a thin layer of RTV sealer GM P/N 12345739 (Canadian P/N 10953541) or equivalent, to the input shaft retainer mating surface. Excessive amounts could plug the bearing oil passage.
19. Install the input shaft retainer. Position the retainer with the oil hole at the top-center position.
    Fig 13: Aligning The Bearing Retainer Oil Drain Hole At The Top Dead Center Position

    Courtesy of GENERAL MOTORS CORP.
20. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the input shaft retainer bolts.
21. Install the input shaft retainer bolts.
    Fig 14: Installing Input Shaft Retainer

    Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the input shaft retainer bolts to 22 N.m (16 lb ft).

22. Position the transmission with the front of the case down.
23. Install the mainshaft rear bearing cup.
24. Temporarily install the mainshaft rear bearing retainer and bolts.
    Fig 15: Installing Mainshaft Rear Bearing Retainer

    Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the mainshaft rear bearing retainer bolts to 35 N.m (26 lb ft).

25. Measure the mainshaft end play. Use the following procedure:
    Fig 16: Measuring Mainshaft End Play

    Courtesy of GENERAL MOTORS CORP.
    1. Using J 26900-13  (2), set the J 8001  (1) on the end of the mainshaft.
    2. Zero out the J 8001  .
    3. Using a screwdriver, or the equivalent, lift the mainshaft and record the measurement.

       The mainshaft end play should be 0.05-0.15 mm (0.002-0.006 in).

    4. Remove the mainshaft rear bearing retainer and bolts.
    5. Add shim(s) under the bearing retainer to achieve the correct end play.
26. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the mainshaft rear bearing retainer bolts.
27. Install the mainshaft rear bearing retainer and bolts.
    Fig 17: Installing Mainshaft Rear Bearing Retainer

    Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the mainshaft rear bearing retainer bolts to 35 N.m (26 lb ft).

28. Install the thrust washer pin in the countershaft.
29. Install the thrust washer. The tapered side faces toward the front of the transmission.
Fig 18: Installing Thrust Washer
Courtesy of GENERAL MOTORS CORP.
30. Lubricate the overdrive gear bearing with transmission fluid.
31. Install the overdrive speed gear bearing.
32. Install the overdrive speed gear assembly onto the overdrive speed shift shaft and the countershaft. Slide the overdrive speed gear fork and the overdrive speed gear assembly onto the shift shaft.
Fig 19: Installing Overdrive Gear Assembly
Courtesy of GENERAL MOTORS CORP.
33. Install the overdrive speed gear clutch gear retainer ring.
    Fig 20: Installing Overdrive Gear Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
34. Install the overdrive speed gear shift fork roll pins. Support the fork, and drive the roll pins downward from the top of the fork.
    Fig 21: Installing Overdrive Gear Shift Fork Roll Pins

    Courtesy of GENERAL MOTORS CORP.
CAUTION: When handling parts that have been preheated for installation purposes, always wear leather welding gloves with a minimum amount of handling time. Failure to wear leather gloves may result in severe skin burns or personal injury.
35. Using the J 25070  , or equivalent, heat the mainshaft overdrive gear, the vehicle speed sensor reluctor wheel for C models for fifteen minutes.
36. Install the mainshaft overdrive gear on the mainshaft.
    Fig 22: Installing Mainshaft Overdrive Gear

    Courtesy of GENERAL MOTORS CORP.
37. Using the J 22828  , ensure the mainshaft overdrive gear is fully seated against the mainshaft rear bearing.
38. For the C model, install the vehicle speed sensor reluctor wheel on the mainshaft.
    Fig 23: Installing VSS Reluctor Wheel (C Model)

    Courtesy of GENERAL MOTORS CORP.
39. Using the J 22828  , ensure the vehicle speed sensor reluctor wheel is fully seated against the mainshaft overdrive gear.
40. For the K model, shift the transmission into two gears, to lock the mainshaft.
41. For the K model, using the J 38805  (1), install a NEW mainshaft washer and the nut. See Special Tools .
    Fig 24: Installing Mainshaft Nut & Washer (K Model)

    Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the mainshaft nut to 540 N.m (400 lb ft).

42. Clean any oil from the sealing surface of the transmission extension and the rear of the case.
43. Apply RTV sealer GM P/N 12345739 (Canadian P/N 10953541) or equivalent on the mating surfaces of the transmission extension.
44. For the K model, install the transmission extension to the transmission case.
    Fig 25: Installing Transmission Extension (K Model)

    Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the bolts to 54 N.m (40 lb ft).

45. For the C model, install the transmission extension to the transmission case.
    Fig 26: Installing Transmission Extension (C Model)

    Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the bolts to 54 N.m (40 lb ft).

46. For the C model, install the vehicle speed sensor (VSS). Lubricate the O-ring for ease of installation.
    Fig 27: Installing VSS And Seal (C Model)

    Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the VSS to 16 N.m (12 lb ft).

47. For the C model, install the yoke assembly.
    Fig 28: Installing Yoke Assembly (C Model)

    Courtesy of GENERAL MOTORS CORP.
48. For the C model, install a NEW spline seal, a NEW washer, and the nut.
49. Use the J 8614-01  to hold the propeller shaft yoke.
    Fig 29: Holding Propeller Shaft Yoke

    Courtesy of GENERAL MOTORS CORP.
50. Shift the transmission into 1st gear, to aid the tightening of the yoke nut.

    Tighten:  Tighten the yoke nut to 441 N.m (325 lb ft).

51. Fill the transmission to the proper level with Synthetic Manual Transmission Fluid GM P/N 12346190 (Canadian P/N 10953477) or equivalent.
52. Apply RTV sealer GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the transmission cover.
    Fig 30: Applying Sealant To Transmission Cover Mating Surfaces

    Courtesy of GENERAL MOTORS CORP.
53. Install the shift cover to the transmission case.
    Fig 31: Installing Shift Cover To Transmission Case

    Courtesy of GENERAL MOTORS CORP.
54. Install the shift cover bolts and the brackets to their original location.

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

55. Apply RTV sealer GM P/N 12345739 (Canadian P/N 10953541) or equivalent, to the shift cover side of the shift tower spacer.
    Fig 32: Applying Sealant To Cover Side Of Shift Tower Spacer

    Courtesy of GENERAL MOTORS CORP.
56. Install the shift tower spacer to the shift cover.
    Fig 33: Installing Shift Lever And Seal

    Courtesy of GENERAL MOTORS CORP.
57. Install the shift lever to the spacer.
58. Install the shift lever bolts and bushings.

    Tighten:  Tighten the bolts to 11 N.m (97 lb in).