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Home >> Chevrolet >> 2009 >> HHR SS, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Manual Transmission - GETRAG 5 Speed) >> Repair Instructions - Off Vehicle >> Transmission Case Disassemble >> Disassembly Procedure

Disassembly Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Transmission Filler Cap
    GM747504Courtesy of GENERAL MOTORS CORP.
  1. Remove the transmission filler cap.
    2. Fig 2: View Of Transmission Drain Plug
    GM747503Courtesy of GENERAL MOTORS CORP.
  2. Remove the transmission drain plug and drain the fluid.
    3. Fig 3: View Of Shift Cable Bracket Assembly
    GM679569Courtesy of GENERAL MOTORS CORP.
  3. Remove the shift cable bracket (4), the spacers (2), the isolators (3) and the bolt (1).
    4. Fig 4: View Of Vehicle Speed Sensor & Bolt
    GM658863Courtesy of GENERAL MOTORS CORP.
  4. Remove the vehicle speed sensor and bolt.
    5. Fig 5: View Of Transaxle Case Side Of Housing Bolt
    GM513865Courtesy of GENERAL MOTORS CORP.
  5. Position the transmission, with the transaxle case side facing up, on a bench.
  6. Remove the seven bolts from the transaxle case side of the housing.
    7. Fig 6: Identifying Intermediate Shaft Seal
    GM513872Courtesy of GENERAL MOTORS CORP.
  7. Turn the transmission over.
    8. CAUTION: Puncture the seal in the center to prevent damage to the transmission.
  8. Remove the intermediate shaft seal using a suitable tool. Discard the seal.
    9. Fig 7: Identifying Plastic Oil Guide
    GM513875Courtesy of GENERAL MOTORS CORP.
  9. Remove the plastic oil guide from the intermediate shaft using a suitable tool. Discard the oil guide.
    10. Fig 8: View Of Transmission & Shifter
    GM513877Courtesy of GENERAL MOTORS CORP.
  10. Turn the transmission so the shifter is on top.
  11. Shift the transmission into any gear.
    12. Fig 9: View Of Intermediate Shaft Bolt
    GM634456Courtesy of GENERAL MOTORS CORP.
  12. Hold the input shaft with J 44377:  tool.
  13. Using the appropriate tool remove the bolt from the intermediate shaft.
    14. Fig 10: View Of Actuator & Tube
    GM881740Courtesy of GENERAL MOTORS CORP.
  14. Remove the actuator and tube bolts.
  15. Remove the actuator and tube.
  16. Inspect the input shaft seal for cuts, nicks, and damage. If damaged, replace the actuator.
    17. Fig 11: View Of Shifter Guide Bolt
    GM513880Courtesy of GENERAL MOTORS CORP.
  17. Shift the transmission into neutral.
  18. Remove the shifter guide bolt.
    19. Fig 12: View Of Shifter And Retaining Bolts
    GM513882Courtesy of GENERAL MOTORS CORP.
  19. Remove the five shifter retaining bolts.
  20. Remove the shifter.
    21. Fig 13: View Of Rear Cover & Bolt
    GM513914Courtesy of GENERAL MOTORS CORP.
  21. Remove the rear cover bolts.
  22. Remove the rear cover.
  23. Remove the oil guide.
    24. Fig 14: View Of Using Screwdriver To Shift Transmission Into 4th & 5th Gear
    GM513921Courtesy of GENERAL MOTORS CORP.
  24. Shift the transmission into 4th and 5th gear using a screwdriver in an upward direction.
  25. Remove the input and output shaft bolts while holding the transmission into 4th and 5th gear with a screwdriver in an upward direction.
    26. Fig 15: View Of Clutch Housing Side Transmission Housing Bolt
    GM513885Courtesy of GENERAL MOTORS CORP.
  26. Turn the transmission over and remove the remainder of the transmission housing bolts from the clutch housing side.
    27. Fig 16: View Of Clutch Housing & Transaxle Case
    GM513889Courtesy of GENERAL MOTORS CORP.
    NOTE: In line with the intermediate shaft, use two suitable tools to assist in the case separation.
  27. Remove the clutch housing from the transaxle case.
    28. Fig 17: View Of Roller Bearing
    GM513908Courtesy of GENERAL MOTORS CORP.
  28. Remove the roller bearing from the output shaft.
    29. Fig 18: View Of Differential
    GM513904Courtesy of GENERAL MOTORS CORP.
  29. Remove the differential from the transaxle case.
    30. Fig 19: View Of Transaxle Case Magnet
    GM514837Courtesy of GENERAL MOTORS CORP.
  30. Remove the magnet from the transaxle case.
    31. Fig 20: View Of Shift Fork
    GM679562Courtesy of GENERAL MOTORS CORP.
  31. Slide outward and unhook the shift rod from the shift fork.
    32. Fig 21: View Of Oil Tube
    GM513926Courtesy of GENERAL MOTORS CORP.
  32. Remove the oil tube from the transaxle case.
    33. Fig 22: View Of Gear Shafts, Shift Forks & Special Tool J 44375
    GM634458Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure all of the shafts are in the proper slots on the holding fixture.
  33. Install the J 44375:  assembly pallet onto the gear shafts and the shift forks.
    34. Fig 23: Turning Transaxle Case On Onto Special Tool J 44375
    GM634459Courtesy of GENERAL MOTORS CORP.
  34. Turn the transaxle case over on the J 44375:  assembly pallet.
    35. Fig 24: View Of Reverse Lamp Switch
    GM514888Courtesy of GENERAL MOTORS CORP.
  35. Remove the reverse lamp switch.
    36. Fig 25: View Of Tightening Jack Screws
    GM658881Courtesy of GENERAL MOTORS CORP.
    NOTE: Alternate the tightening of the jack screws on the J 44376:  pusher/puller to ensure proper removal of the transaxle case.
  36. Remove the transaxle case from the shafts using the J 44376-1, J 44376-2, and J 44376-3.
    37. Fig 26: View Of Intermediate Shaft & Shift Fork
    GM634460Courtesy of GENERAL MOTORS CORP.
  37. Remove the intermediate shaft and shift fork from the input shaft, the output shaft, and the J 44375:  assembly pallet.
    38. Fig 27: View Of Gear Assemblies & Shift Forks
    GM634461Courtesy of GENERAL MOTORS CORP.
  38. Remove the shift forks from the gear assemblies.
  39. Remove the remaining gear assemblies from the holding fixtures.
    40. Fig 28: Identifying Special Tools J 23907 & J 44380
    GM658874Courtesy of GENERAL MOTORS CORP.
  40. Using the J 44380:  race puller (2) and the J 23907:  bearing adapter (1), remove the differential bearing outer race from the clutch housing. Discard the race.
    41. Fig 29: View Of Differential Output Shaft Seal
    GM756689Courtesy of GENERAL MOTORS CORP.
  41. Remove the differential output shaft seal from the clutch housing. Discard the seal.
    42. Fig 30: Identifying Output Shaft Bearing Race, Bolts, Special Tool J 23907 & J 44380
    GM658875Courtesy of GENERAL MOTORS CORP.
  42. Remove the output shaft bearing race and bolts from the clutch housing using the J 23907:  bearing adapter (1) and the J 44380:  race puller (2).
    43. Fig 31: Locating Input Shaft Bearing
    GM658856Courtesy of GENERAL MOTORS CORP.
  43. Remove the input shaft bearing from the clutch housing using the J 44381:  bearing remover and J 7079-2:  driver handle.
    44. Fig 32: View Of Counter Shaft Bearing & Shaft Ring
    GM797566Courtesy of GENERAL MOTORS CORP.
  44. Remove the snap ring from the counter shaft bearing.
  45. Remove the counter shaft bearing from the clutch housing using the J 44381:  bearing remover (2) and the J 7079-2:  driver handle (1).
    46. Fig 33: View Of Removing Differential Bearing Outer Race
    GM658857Courtesy of GENERAL MOTORS CORP.
  46. Remove the differential bearing outer race from the transmission housing using the J 44380:  race puller (2) and the J 23907:  bearing adapter (1). Discard the race.
    47. Fig 34: View Of Differential Output Shaft Seal
    GM658876Courtesy of GENERAL MOTORS CORP.
  47. Remove the differential output shaft seal from the transmission housing. Discard the seal.
    48. Fig 35: View Of Transmission Housing Bolt, Spring & Lever
    GM658860Courtesy of GENERAL MOTORS CORP.
  48. Remove the reverse lockout lever bolt (1), lever (3) and spring (2) from the transmission housing, if equipped.
    49. Fig 36: Identifying J 44381 & J 7079-2
    GM658858Courtesy of GENERAL MOTORS CORP.
  49. Remove the shifter bearing from the transmission housing using the J 44381:  bearing remover (1) and the J 7079-2:  driver handle (2).
    50. Fig 37: View Of Intermediate Shaft Needle Bearing & Special Tools J 44380 & J 23907
    GM658864Courtesy of GENERAL MOTORS CORP.
  50. Remove the intermediate shaft needle bearing from the transmission housing using the J 44382:  bearing puller (2) and the J 23907:  bearing adapter (1).
    51. Fig 38: View Of Shift Rod & Bushing
    GM658859Courtesy of GENERAL MOTORS CORP.
  51. Remove the shift rod bushing and the shift rod from the transmission housing.
    52. Fig 39: Identifying Special Tools J 44385 & J 8092
    GM658855Courtesy of GENERAL MOTORS CORP.
  52. Remove the input and output shaft bearing with snap ring from the transmission housing using the J 44385:  installer (2) and the J 8092:  handle (1).
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