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Transmission Disassemble: Disassemble

WARNING: This page is about a different car, the 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Backup Lamp Switch
    GM1619483Courtesy of GENERAL MOTORS CORP.
    NOTE: In all work involving disassembly of the transaxle, a new output shaft nut and crush sleeve must be installed during reassembly.
  1. Remove the backup lamp switch to prevent the switch from being damaged during disassembly.
  2. Cover the holes for clutch hydraulics, axles, and the reverse lamp switch, and clean the transaxle if necessary.
    3. Fig 2: Mounting Transaxle On J 43707
    GM895488Courtesy of GENERAL MOTORS CORP.
  3. Mount the transaxle on J 43707:  support fixture. Mount the transaxle and fixture in the J 43964:  fixture adapter.
    4. Fig 3: View Of Pipe At Slave Cylinder
    GM895568Courtesy of GENERAL MOTORS CORP.
  4. Remove the pipe from the slave cylinder.
  5. Using pliers, pinch together the bottom halves of the pipe sleeve and move the pipe and sleeve upward.
    6. Fig 4: Prying Up Locking Tabs
    GM895576Courtesy of GENERAL MOTORS CORP.
  6. Pry up the locking tabs on the sleeve and remove the pipe.
    7. Fig 5: View Of Slave Cylinder
    GM895580Courtesy of GENERAL MOTORS CORP.
  7. Remove the slave cylinder bolts and slave cylinder.
  8. Remove the reverse idler gear shaft bolt with an O-ring.
    9. Fig 6: View Of Transaxle Rear Cover
    GM895031Courtesy of GENERAL MOTORS CORP.
  9. Remove the transaxle rear cover and discard the gasket. Note the stud locations.
    10. Fig 7: Engaging 1st Gear To Lock Gear Box
    GM1883849Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not shift gears using the 1st/2nd, 3rd/4th, or 5th shift shafts. All shifting should be done using the shift arms.
  10. Engage the 1st gear to lock the gear box. Refer to the shift arm positions in the illustration.
  11. Using a punch and hammer, tap out the 5th gear fork retaining pin.
    12. Fig 8: View Of Output Shaft Nut
    GM1227214Courtesy of GENERAL MOTORS CORP.
  12. Engage the 5th gear by pressing the synchronizer sleeve and fork down onto the 5th gear. Two gears must be engaged at the same time to allow removal of output shaft nut.
  13. Pry up the locking tab on the output shaft nut and remove the nut.
    14. Fig 9: View Of 5th Gear Shift Fork & Synchronizer Sleeve
    GM1227215Courtesy of GENERAL MOTORS CORP.
    NOTE: Before removing the 5th gear synchronizer sleeve, mark its position relative to the 5th gear synchronizer hub to assist in assembly.
    NOTE: Make sure the 5th gear shift shaft does not come out of the transaxle when the 5th gear shift fork is removed.
  14. Remove the 5th gear shift fork and synchronizer sleeve together.
    15. Fig 10: Removing 5th Gear Synchronizer Hub & Snap Ring
    GM895037Courtesy of GENERAL MOTORS CORP.
  15. Remove the 5th gear synchronizer hub snap ring. This will be easier if the hub is tapped down first.
  16. Use the J 25031-A:  jaw puller or equivalent to remove the 5th gear synchronizer hub.
  17. Remove the blocking ring, blocking ring spring, 5th gear, and 5th gear bearing assembly.
    18. Fig 11: View Of Differential Bearing Retainer
    GM1227193Courtesy of GENERAL MOTORS CORP.
  18. Remove the differential bearing retainer fasteners. The retainer will be removed after case removal.
    19. Fig 12: View Of Case-To-Clutch Housing Bolts
    GM895040Courtesy of GENERAL MOTORS CORP.
  19. Remove the case-to-reverse idler gear shaft bracket bolt. Note the stud locations.
    20. NOTE: Before removing the transaxle case from the transaxle clutch housing, the case-to-reverse idler gear shaft bracket bolt must be removed or transaxle damage will occur.
  20. Remove the case-to-clutch housing bolts and tap down 2 case-to-clutch housing alignment sleeves.
    21. Fig 13: Removing Case From Output Shaft
    GM895043Courtesy of GENERAL MOTORS CORP.
  21. Remove the case from the output shaft.
    1. Check that 3rd gear is engaged.
    2. Install the 87 92 129:  lifting eye to the case.
    3. Install the 87 91 410:  protector to the output shaft.
    4. Install the 87 91 287:  puller with the 87 91 303:  puller arms, 150 mm into the pulling eyes.
    5. Carefully tighten the puller until the output shaft bearing and 5th driven gear releases from the output shaft.
    22. Fig 14: Locating Differential Bearing Retainer
    GM895546Courtesy of GENERAL MOTORS CORP.
  22. Remove tools. Lift off transaxle case.
  23. Remove differential bearing retainer from transaxle case.
  24. Inspect the O-ring seal and axle seal for damage. Replace if damaged.
  25. Remove shims from the top of bearing race.
    26. Fig 15: View Of 87-92-202 & 87-91-204
    GM895047Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not re-install the bearing race until after the shimming procedure.
  26. Tap out differential bearing race using 87 92 202:  sleeve and 87 91 204:  sleeve.
    27. Fig 16: View Of Reverse Gear Fork & Shaft
    GM1407799Courtesy of GENERAL MOTORS CORP.
  27. Remove the reverse gear fork and shaft.
    28. Fig 17: View Of Reverse Shift Lever Assembly
    GM895053Courtesy of GENERAL MOTORS CORP.
  28. Remove the reverse shift lever assembly and bolts.
    29. Fig 18: View Of Shift Linkage Assembly
    GM1407800Courtesy of GENERAL MOTORS CORP.
  29. Disengage the reverse on the shift linkage assembly. Remove the remaining shift linkage bolt and lift the mechanism slightly. Remove the locating sleeves.
  30. Put the transaxle in 2nd gear and remove the shift linkage assembly by moving it rearward, towards the differential, and angling it out while lifting.
    31. Fig 19: View Of Reverse Idler Gear Shaft Assembly
    GM895064Courtesy of GENERAL MOTORS CORP.
  31. Install the reverse idler gear shaft bracket bolt finger tight.
  32. Lift the input shaft far enough to allow removal of the reverse idler gear shaft assembly.
  33. Remove the reverse idler gear shaft bolt and remove the reverse idler gear shaft.
    34. Fig 20: View Of 4th Driven Gear, Crush Sleeve & Spacer Sleeve
    GM1619497Courtesy of GENERAL MOTORS CORP.
  34. Remove the 4th driven gear, crush sleeve, and spacer sleeve from the output shaft.
    35. Fig 21: Installing 87-92-103
    GM1227188Courtesy of GENERAL MOTORS CORP.
  35. Install the 87 92 103:  tool around the 1st gear and 1st/2nd gear synchronizer sleeve as shown. This tool holds the 1st and 2nd synchronizer assemblies together. Secure the tool with a plastic tie.
    36. Fig 22: Removing Input Shaft
    GM895069Courtesy of GENERAL MOTORS CORP.
  36. Install the 87 91 410:  protector on the output shaft.
  37. Install the 87 90 867:  ring with the 87 91 295:  puller arms, 300 mm under the 1st driven gear of the output shaft.
  38. Carefully tighten the puller until the remaining output shaft gears are up far enough to allow the removal of the input shaft, approximately 15 mm (0.6 in).
  39. Remove the input shaft.
    40. Fig 23: Removing Puller & Gears From Output Shaft
    GM895072Courtesy of GENERAL MOTORS CORP.
    NOTE: Note the up/down orientation of the 3rd driven gear. If the old gear is reinstalled, it must be installed in the same orientation to avoid noise concerns.
  40. Continue pulling the driven gears on the output shaft until all gears are loose.
  41. Remove the puller and gears from the output shaft.
    42. Fig 24: Removing Output Shaft Bearing Retainer Bolts
    GM895074Courtesy of GENERAL MOTORS CORP.
    CAUTION: The output shaft bearing retainer bolts were installed using a threadlocker at the factory. A J43483 impact driver or equivalent must be used to remove these bolts or the bolt heads may strip out requiring additional repair time.
  42. Remove the output shaft bearing retainer bolts using the J 43483:  impact driver or equivalent and remove the retainer.
    43. Fig 25: Removing Output Shaft
    GM895077Courtesy of GENERAL MOTORS CORP.
  43. Remove the output shaft using the 87 91 188:  press support, the 87 91 972:  assembly ring, and the87 91 261:  remover.
    44. Fig 26: View Of Differential Assembly
    GM1227206Courtesy of GENERAL MOTORS CORP.
  44. Remove the differential assembly.
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