Transmission Disassemble

Special Tools

• DT-47678:  Transmission Holding Fixture
• DT-47678-10:  Transmission Holding Fixture Adapter
• DT-49027:  Coil Pin Remover and Installer
• J 3289-20:  Holding Fixture
• J 6125-1B:  Slide Hammer with Adapter
• J 8433:  Two Jaw Puller
• J 35467:  One-Way Clutch Tester
• J 41816:  Crankshaft Balancer Remover
• J 45012:  Holding Fixture

For equivalent regional tools, refer to Special Tools .

Fig 1: Transmission Mounting Fixture & Adapters
Courtesy of GENERAL MOTORS CORP.
1. Install DT-47678:  fixture (2) and DT-47678-10:  adapters (3) to the transmission clutch housing.
2. Mount the transmission to a workbench using J 3289-20:  fixture (1).
3. Remove the clutch release cylinder bolts and the clutch release cylinder. Refer to Clutch Concentric Actuator Cylinder Replacement (Aisin) or Clutch Concentric Actuator Cylinder Replacement (Tremec) .
Fig 2: Identifying Fill Plug, Drain Plug & Washers
Courtesy of GENERAL MOTORS CORP.
4. Remove the fill plug (79) and the washer (33).
5. Remove the drain plug (34) and the washer (33) then drain the transmission fluid.
Fig 3: Identifying Backup Lamp Switch & Washer
Courtesy of GENERAL MOTORS CORP.
6. Remove the backup lamp switch and washer (208) from the case.
Fig 4: Output Sensor & Bolt
Courtesy of GENERAL MOTORS CORP.
7. Remove the output sensor (213) and bolt (215) from the rear extension housing.
Fig 5: Coil Pin Puller & Slide Hammer
Courtesy of GENERAL MOTORS CORP.
NOTE: Prior to the shift lever pin removal, the shift control shaft must be shifted forward into the transmission.
8. Install DT-49027-1:  coil pin puller (2) onto J 6125-1B:  slide hammer (1).
9. Position DT-49027-1:  puller (2) directly beneath the shift lever pin (41), then repeatedly pull up on the slide hammer handle until the bottom of the shift lever pin is flush with the machined O.D. of the shift lever rod universal joint.
Fig 6: Tightening Coil Pin Remover
Courtesy of GENERAL MOTORS CORP.
NOTE: Only rotate the wrench attached to the outer body of DT-49027-2:  coil pin remover. The wrench attached to the inner body must remain stationary.
10. Install DT-49027-2:  coil pin remover (2) onto the top of the shift lever pin (41) and tighten.
11. Install J 6125-1B:  slide hammer (1) onto DT-49027-2:  coil pin remover (2). Repeatedly, pull up on the slide hammer handle until the shift lever pin (41) is removed from the shift lever rod universal joint.
Fig 7: Shift Lever Rod Universal Joint & Dampener
Courtesy of GENERAL MOTORS CORP.
12. Remove the shift lever rod universal joint (40) and dampener (102) from the end of the shift control shaft.
Fig 8: Removing Propshaft Flange Nut & Propshaft Flange Fluid Seal
Courtesy of GENERAL MOTORS CORP.
13. Using a screwdriver, release the staking of the propshaft flange nut (126).
14. Install J 45012:  fixture to the propshaft flange (108) to remove the propshaft flange nut (126) and propshaft flange fluid seal (193).
Fig 9: Removing Propshaft Flange
Courtesy of GENERAL MOTORS CORP.
15. Using J 41816:  remover to remove the propshaft flange (108).
Fig 10: Identifying Extension Housing & Bolts
Courtesy of GENERAL MOTORS CORP.
16. Remove the 8 bolts (93) from the extension housing (86).
17. Remove the extension housing.
Fig 11: View Of Vehicle Speed Sensor Drive Gear, Spacer, Locking Ball & Main Shaft Bearing Oil Slinger
Courtesy of GENERAL MOTORS CORP.
18. Remove the rear output shaft rear bearing spacer (191).
19. Remove the vehicle speed sensor drive gear (212).
20. Remove the locking ball (214).
21. Remove the main shaft bearing oil slinger (107).
Fig 12: Removing/Installing Clutch Housing Hole Plug
Courtesy of GENERAL MOTORS CORP.
22. Using J 35467:  clutch tester, remove the clutch housing hole plug (30) from the clutch housing.
Fig 13: View Of Shift Shaft Detent Plug, Spring & Pin
Courtesy of GENERAL MOTORS CORP.
23. Remove the following components:
    • The shift shaft detent plug (36)
    • The shift shaft detent spring (75)
    • The shift shaft detent pin (68)
Fig 14: View Of Rear Case Housing Retainer & Bolts
Courtesy of GENERAL MOTORS CORP.
24. Remove the 10 bolts (27) and retainer (209) from the rear case housing.
CAUTION: Refer to Machined Surface Damage Caution .
25. Using a soft-face hammer, separate the rear case housing from the intermediate case housing.
26. Remove the rear case housing.
Fig 15: Oil Trough Bolts & Oil Trough
Courtesy of GENERAL MOTORS CORP.
27. Remove the 2 oil trough bolts (37) and oil trough (20).
Fig 16: Identifying Oil Trough Pipe, Reverse Idler Gear Shaft Bolt & Gasket
Courtesy of GENERAL MOTORS CORP.
28. Remove the oil trough pipe (19).
29. Remove the reverse idler gear shaft bolt (35) and gasket (32).
Fig 17: View Of Clutch Housing Bolts
Courtesy of GENERAL MOTORS CORP.
30. Remove the 11 flange bolts retaining the clutch housing. This includes 8 bolts from the front and 3 bolts from the rear.
Fig 18: View Of Intermediate Case Housing
Courtesy of GENERAL MOTORS CORP.
CAUTION: Refer to Machined Surface Damage Caution .
NOTE: Rotate case to avoid interference with shift fork.
31. Using a soft-face hammer, separate the intermediate case from the front clutch housing.
32. Remove the intermediate case housing.
Fig 19: View Of Shift Shaft Selector Lever
Courtesy of GENERAL MOTORS CORP.
33. Remove the shift shaft selector lever.
Fig 20: View Of Rear Output Shaft, Input Shaft Bearing & Blocking Ring
Courtesy of GENERAL MOTORS CORP.
34. Remove the rear output shaft (111), input shaft bearing (137) and blocking ring (121) from the 6th gear synchronizer assembly.
Fig 21: View Of Reverse Idler Gear, Bearing & Shaft
Courtesy of GENERAL MOTORS CORP.
35. Remove the reverse idler gear bearing (136), reverse idler gear (205) and the reverse idler gear shaft (204).
Fig 22: View Of Shift Counter Lever Bracket Bolts
Courtesy of GENERAL MOTORS CORP.
36. Remove the 4 bracket bolts from the shift counter lever bracket.
Fig 23: Front Countershaft Bearing Snap Ring
Courtesy of GENERAL MOTORS CORP.
NOTE: The removal of the input shaft and counter shaft assemblies will require an assistant.
37. Expand and hold the snap ring on the front countershaft bearing.
Fig 24: Holding Snap Ring On Rear Input Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
38. Expand and hold the snap ring on the rear input shaft bearing.
Fig 25: View Of Input Shaft, Countershaft & Shift Rail Assembly
Courtesy of GENERAL MOTORS CORP.
39. Remove the input shaft, countershaft and shift rails as an assembly.
Fig 26: Disassembling/Assembling Shift Rails, Input Shaft & Countershaft
Courtesy of GENERAL MOTORS CORP.
40. Separate the shift rails, the input shaft and countershaft.