Transmission Assemble: Notes

Special Tools

• DT-47678:  Transmission Holding Fixture
• DT-49027:  Coil Pin Remover and Installer
• J 3289-20:  Holding Fixture
• J 35467:  One-Way Clutch Tester
• J 44731:  Input Shaft Seal Installer
• J 45012:  Holding Fixture

For equivalent regional tools, refer to Special Tools .

Fig 1: Disassembling/Assembling Shift Rails, Input Shaft & Countershaft
Courtesy of GENERAL MOTORS CORP.
1. Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) to each gear shift fork and gear shift head. Join the shift rail assembly to the input shaft and countershaft assembly.
Fig 2: View Of Input Shaft, Countershaft & Shift Rail Assembly
Courtesy of GENERAL MOTORS CORP.
2. With assistance install the input shaft, countershaft and shift rails as an assembly in the clutch housing.
Fig 3: Holding Snap Ring On Rear Input Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
3. With assistance install the snap ring into the groove of the input shaft radial ball bearing.
Fig 4: Front Countershaft Bearing Snap Ring
Courtesy of GENERAL MOTORS CORP.
4. With assistance install the snap ring into the groove of the countershaft radial ball bearing.
Fig 5: View Of Shift Counter Lever Bracket Bolts
Courtesy of GENERAL MOTORS CORP.
5. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the shift rail bolts.
CAUTION: Refer to Fastener Caution .
6. Install the 4 shift rail bolts and tighten to 21 N.m (15 lb ft).
Fig 6: View Of Reverse Idler Gear, Bearing & Shaft
Courtesy of GENERAL MOTORS CORP.
NOTE: During alignment, ensure that the thread hole of the reverse idler gear shaft (204) aligns with the thread hole of the middle case.
7. Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) and install the following components:
   • The reverse idler gear bearing (136)
   • The reverse idler gear (205) with the higher boss facing the rear
   • The reverse idler gear shaft (204) with its hole facing outward
Fig 7: Shift Shaft Selector Lever
Courtesy of GENERAL MOTORS CORP.
8. Apply sealer GM P/N 89020326 (Canadian P/N 89021188) or equivalent to the interface of either case.
9. Install the shift shaft selector lever.
Fig 8: Select Lever Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
CAUTION: Refer to Machined Surface Damage Caution .
NOTE: Rotate case to avoid interference with shift fork.
10. Apply sealer GM P/N 89020326 (Canadian P/N 89021188) or equivalent to the interface of either case.
11. Apply lubricant GM P/N 88862475 (Canadian P/N 88862476 to the shift and select lever shaft bearing.
12. Install the intermediate case housing.
Fig 9: View Of Clutch Housing Bolts
Courtesy of GENERAL MOTORS CORP.
13. Install the 8 bolts from the clutch housing and the 3 bolts from the middle case. Tighten the bolts to 40 N.m (29 lb ft).
Fig 10: View Of Rear Output Shaft, Input Shaft Bearing & Blocking Ring
Courtesy of GENERAL MOTORS CORP.
14. Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) and install the input shaft bearing (137), blocking ring (121) and the rear output shaft (111).
Fig 11: Identifying Oil Trough Pipe, Reverse Idler Gear Shaft Bolt & Gasket
Courtesy of GENERAL MOTORS CORP.
15. Install the oil trough pipe (19).
16. Install a NEW gasket (32) and the bolt (35) to secure the reverse idler shaft. Tighten the bolt to 40 N.m (30 lb ft).
Fig 12: Oil Trough Bolts & Oil Trough
Courtesy of GENERAL MOTORS CORP.
17. Install the oil trough (20) and the 2 oil trough bolts (37) and tighten to 8.5 N.m (75 lb in).
Fig 13: Applying Lubricant To Cylindrical Roller Bearing, Outer Race & Control Sub-Assembly Holes
Courtesy of GENERAL MOTORS CORP.
18. Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) to the following components:
    • The tapered roller bearing outer race
    • The cylindrical roller bearing
    • The control sub-assembly holes
Fig 14: Applying Lubricant To Tapered Roller Bearing & Cylindrical Roller Bearing Inner Race
Courtesy of GENERAL MOTORS CORP.
19. Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) to the following components:
    • The tapered roller bearing of the output shaft
    • The cylindrical roller bearing inner race of counter gear
Fig 15: View Of Rear Case Housing Retainer & Bolts
Courtesy of GENERAL MOTORS CORP.
20. Apply sealer GM P/N 89020326 (Canadian P/N 89021188) or equivalent to the clean interface of either case.
CAUTION: Refer to Machined Surface Damage Caution .
NOTE: Use care when installing the rear case housing so that the oil receiver is not damaged.
21. Install the rear case housing.
22. Install the 10 bolts (27) and retainer (209) to the rear case housing. Tighten the bolts to 40 N.m (29 lb ft).
Fig 16: View Of Shift Shaft Detent Plug, Spring & Pin
Courtesy of GENERAL MOTORS CORP.
23. Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) and install the lock ball pin (68).
24. Install the spring (75) and a NEW plug (36). Tighten the plug to 24.5 N.m (18 lb ft).
Fig 17: Removing/Installing Clutch Housing Hole Plug
Courtesy of GENERAL MOTORS CORP.
25. Using J 35467:  tester, install a NEW clutch housing hole plug (30) into the clutch housing. Tighten the bolt to 39.3 N.m (29 lb ft).
Fig 18: Installing Input Shaft Seal
Courtesy of GENERAL MOTORS CORP.
26. Using J 44731:  installer, install a NEW input shaft seal (12).
Fig 19: View Of Vehicle Speed Sensor Drive Gear, Spacer, Locking Ball & Main Shaft Bearing Oil Slinger
Courtesy of GENERAL MOTORS CORP.
27. Align and install the main shaft bearing oil slinger (107).
28. Grease and install the locking ball (214).
29. Align and install the vehicle speed sensor drive gear (212).
30. Install a NEW rear output shaft rear bearing spacer (191).
Fig 20: Identifying Extension Housing & Bolts
Courtesy of GENERAL MOTORS CORP.
31. Apply sealer GM P/N 89020326 (Canadian P/N 89021188) or equivalent to the interface of either case.
32. Install the rear extension housing.
33. Install the 8 bolts (93) into the rear extension housing (86) and tighten to 29 N.m (21 lb ft).
Fig 21: Identifying Dampener & Shift Lever Rod Universal Joint
Courtesy of GENERAL MOTORS CORP.
34. Install the dampener (102) and shift lever rod universal joint (40) on the end of the shift control shaft.
Fig 22: Installing Shift Lever Pin
Courtesy of GENERAL MOTORS CORP.
NOTE: Prior to shift lever pin installation, the shift control shaft must be shifted forward into the transmission.
35. Position and align the shift lever pin (41) with the hole in the shift lever rod universal joint. Use DT-49027-3:  coil pin installer and a mallet to install the pin (41) to the proper depth.
Fig 23: Propshaft Flange Components
Courtesy of GENERAL MOTORS CORP.
36. Install the propshaft flange (108).
37. Grease and install a NEW propshaft flange fluid seal (193).
38. Install a NEW propshaft flange nut (126).