Extension Disassemble

Special Tools

• DT 49216:  Shift Rail Bearing Remover
• J 23907:  Slide Hammer with Bearing Adapter
• J 26941:  Bearing Race Remover
• J 29369-2:  Bushing and Bearing Remover - 2-3 in
• J 36190:  Universal Driver Handle
• J 39431:  Fifth/Sixth Driven Gear Puller
• J 39439-1:  Bushing Installer
• J 39439-2:  Shift Rail Bushing Remover
• J 39439-3:  Bushing Installer
• J 45124:  Removal Bridge
• J 45124-9:  Puller Leg

For equivalent regional tools, refer to Special Tools .

Fig 1: View Of Reverse Idler Shaft Bracket & Bolts
Courtesy of GENERAL MOTORS CORP.
1. Remove the reverse idler shaft bracket bolts and bracket.
Fig 2: View Of Reverse Idler Gear & Roller Bearing
Courtesy of GENERAL MOTORS CORP.
2. Remove the reverse idler gear and the roller bearing.
Fig 3: Identifying Reverse Idler Gear Shaft
Courtesy of GENERAL MOTORS CORP.
3. Remove the reverse idler gear shaft (1).
Fig 4: View Of Countershaft Rear Bearing Retainer
Courtesy of GENERAL MOTORS CORP.
4. Remove the countershaft rear bearing retainer (1).
NOTE: The plastic roller bearing cage (2) and bearings are part of the countershaft bearing assembly. Always use a new countershaft bearing assembly.
5. Cut away the plastic roller bearing cage (2) from the countershaft bearing assembly.
6. Remove the bearings (3). Discard the cage and bearings.
Fig 5: Removing Race
Courtesy of GENERAL MOTORS CORP.
7. Install J 45124-1:  removal bridge (1), J 45124-9:  puller leg (2), and J 29369-2:  remover (3) in the race from the countershaft bearing assembly in the extension housing.
8. Remove the race.
Fig 6: View Of Oil Funnel & Bearing Race
Courtesy of GENERAL MOTORS CORP.
NOTE: The bearing race is part of the countershaft bearing assembly. Always use a new countershaft bearing assembly.
9. Remove the oil funnel (1) from the bearing race (2). Discard the bearing race.
Fig 7: Removing Bushing
Courtesy of GENERAL MOTORS CORP.
10. Using J 39439-2:  remover (2) and J 23907:  slide hammer (1), remove the bushing.
Fig 8: Identifying Output Shaft Seal
Courtesy of GENERAL MOTORS CORP.
11. Remove the output shaft seal (1).

    Pry out the seal with a suitable tool.

Fig 9: Identifying Roller Bearing & Snap Ring
Courtesy of GENERAL MOTORS CORP.
12. Remove the snap ring (1) and the roller bearing (2).
Fig 10: Identifying Reverse Lockout Assembly
Courtesy of GENERAL MOTORS CORP.
13. Remove the mounting bolt, the reverse lockout assembly (1) and the O-ring.
Fig 11: Identifying Transmission Case Drain Plug & Vehicle Speed Sensor
Courtesy of GENERAL MOTORS CORP.
14. Remove the bolt and the vehicle speed sensor (1).
15. Remove the plug (2).
Fig 12: Identifying Mainshaft Bearing Race Retainer Ring
Courtesy of GENERAL MOTORS CORP.
16. Remove the mainshaft bearing race retainer ring (1).
Fig 13: Removing Mainshaft Bearing Race
Courtesy of GENERAL MOTORS CORP.
NOTE: Do not replace the bearing race unless inspection shows bearing race damage.
17. Place the extension housing on a flat work surface. Locate the oil clearance gap between the housing and the main shaft bearing race.
18. Insert a brass drift (1) through the mainshaft opening of the extension housing, into the oil clearance gap. Using a mallet, tap down on the drift to remove the mainshaft bearing race (2).
Fig 14: Removing Reverse Rail Bushing
Courtesy of GENERAL MOTORS CORP.
19. Remove the reverse rail bushing using the J 36190:  handle (1) and J 39439-2:  installer (2).
Fig 15: Identifying Rear Housing Shift Rail Seal
Courtesy of GENERAL MOTORS CORP.
20. Remove the rear housing shift rail seal (1).
Fig 16: Removing Shift Rail Bearing
Courtesy of GENERAL MOTORS CORP.
21. Remove the shift rail bearing using the J 23907:  slide hammer (1) and DT 49216:  remover (2).