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Input and Main Shaft Bearing Installation

WARNING: This page is about a different variant/trim than selected.

Special Tools

For equivalent regional tools, refer to Special Tools .

NOTE:

If the transmission is still within the normal warranty, please contact the DLT / mobile service responsible (if available). The DLT / mobile service will decide on what further action is to be taken. The repair described in this procedure only applies to transmissions up to model year 12.5.

Diagnosis: The transmission shaft bearing must be changed under the following conditions:

  • Milling, shearing noises in 5th or 6th gear (if there is advanced bearing failure in all other gears).
  • Gear lever movement during load change 1/2 or 5/6 gear (in conjunction with the noises mentioned above).
NOTE:

Damage investigation / assessment: If you can see that the outer gear shaft bearings are badly damaged when removing the transmission case cover (bearing "disintegrated" or no longer intact), please contact DLT / mobile service (if available) responsible. DLT / mobile service will decide on what further action should be taken.

NOTE:

Transmission repair kit identification: some technical modifications were introduced during transmission manufacture. The corresponding repair kits can be assigned to the transmission housing via the transmission number. If the transmission number on the transmission housing is no longer visible, it can be determined via the VIN on GM drive. If the VIN is not known, the repair kit can be assigned by measuring the transmission shaft diameter or by counting the teeth on gearwheel for 1st gear (further information can be found in the following work procedures).

NOTE:

The components of the transmission shafts must not be dropped or bumped! Dropped or bumped parts must not be installed!

NOTE:

Ambient temperature must be between 15-25 °C (59-77 °F).

    Fig 1: Input Shaft
    GM2811173Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    In the M20 / M32 transmissions, input shafts with two different transmission shaft diameter in the region of the input shaft seal ring may be fitted. The appropriate repair kit can be assigned based on the transmission shaft diameter and the number of teeth of the gearwheel for the 1st gear on the lower main shaft.

  1. Measure the diameter of the input shaft (1).
    1. Measure in the area "X" (arrows).
      • Diameter: 24.5 mm (0.96 in)
      • Diameter: 26.0 mm (1.02 in)
    2. Note the measured value.
    2. Fig 2: 1st Gear
    GM2811176Courtesy of GENERAL MOTORS COMPANY
  2. Count the teeth of the 1st gear gearwheel (1).
    1. Quantity:
      • 42 teeth
      • 47 teeth
    2. Note the quantity of the counted teeth.
  3. Choose the correct repair kit.
    • Via GM-Drive and the VIN or via the list below, using input shaft diameter and quantity teeth 1st gear gearwheel.
    1. Repair kit 1: Input shaft diameter 24.5 mm (0.96 in) and 1st gear gearwheel with 42 teeth.
      • Part number refer to EPC catalog.
      • For MZ0, MZ4 (M32), M85 (M20 MTA).
    2. Repair Kit 2: Input shaft diameter 24.5 mm (0.96 in) and 1st gear gearwheel with 47 teeth.
      • Partnumber refer to EPC catalog.
      • For MZ7 (M20), M81 (M20 MTA).
    3. Repair Kit 3: Input shaft diameter 26.0 mm (1.02 in) and 1st gear gearwheel with 42 teeth.
      • Partnumber refer to EPC catalog.
      • For MZ0, MZ4, M06 (M32), M85 (M20 MTA).
    4. Repair Kit 4: Input shaft diameter 26.0 mm (1.02 in) and 1st gear gearwheel with 47 teeth.
      • Partnumber refer to EPC catalog.
      • For MF3, MR5, M60, M3N (M32), MZ7 (M20).
    4. Fig 3: Input Shaft Support Sleeve
    GM2811197Courtesy of GENERAL MOTORS COMPANY
  4. Support the input shaft using the DT-60000-60  sleeve (2). Make sure to use the correct function side of the DT-60000-60  sleeve, according to the input shaft diameter.
  5. Press on NEW outer bearing (3) to the input shaft, using the DT-6339  installer (1).
    6. Fig 4: Input Shaft And Bolt
    GM2811177Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Input shaft thread must be free from oil and grease.

  6. Clamp input shaft (1) into a vise (3), using aluminum protective jaws (2).
  7. Apply thread lock agent to the NEW input shaft bolt (4).
    8. CAUTION:

    Refer to Fastener Caution .

  9. Install NEW input shaft bolt to the input shaft and tighten to 65 N.m (48 lb ft).
    10. Fig 5: Pressing Inner Bearing On Input Shaft
    GM2811201Courtesy of GENERAL MOTORS COMPANY
  10. Press on NEW inner bearing (2) to the input shaft, using the DT-60000-60  sleeve (1). Make sure to use the correct function side of the DT-60000-60  sleeve according to the input shaft diameter.
    11. Fig 6: Special Tool Support Sleeve
    GM2811251Courtesy of GENERAL MOTORS COMPANY
  11. Support the upper main shaft inner bearing (1), using the DT-46759  sleeve (2).
  12. Install the inner bearing to the upper main shaft. Press in the upper main shaft.
    13. Fig 7: Inner Bearing Retaining Ring
    GM2811253Courtesy of GENERAL MOTORS COMPANY
  13. Measure the fitting of the NEW inner bearing retaining ring (1). Try different thicknesses of retaining ring.
    • Retaining ring must not fit loosely into the groove.
    • Too huge retaining ring can grind or block the reverse gear gearwheel.
    • Use the thickest retaining ring possible.
    14. Fig 8: Retaining Ring Clamps
    GM2811247Courtesy of GENERAL MOTORS COMPANY
  14. Install NEW inner bearing retaining ring (1) to the upper main shaft, using the GE-396  pliers.
    15. Fig 9: Reverse Gear Needle Bearing And Upper Main Shaft
    GM2811243Courtesy of GENERAL MOTORS COMPANY
  15. Install the reverse gear needle bearing (1) to the upper main shaft.
    16. Fig 10: Installing Reverse Gearwheel To Upper Main Chaff
    GM2811255Courtesy of GENERAL MOTORS COMPANY
  16. Install the reverse gear gearwheel (1) to the upper main shaft.
    17. Fig 11: Installing Synchronizer Ring
    GM2811257Courtesy of GENERAL MOTORS COMPANY
  17. Install the synchronizer ring (1) to the reverse gear gearwheel.
    18. Fig 12: Spring Catches And Reverse Gear Sleeve Carrier
    GM2811259Courtesy of GENERAL MOTORS COMPANY
  18. Install the 3 spring catches (1) to the reverse gear sleeve carrier (2).
    19. NOTE:

    Make sure that the position and direction of installation is correct.

  19. Install the reverse gear selector sleeve to the reverse gear sleeve carrier.
    • The peaked teeth (lower arrow) of the selector sleeve are orientated toward the reverse gear gearwheel.
    • The pits in the selector sleeve (upper arrow) must be installed in the position of the spring catches.
    20. Fig 13: Sleeve Carrier Assembly
    GM2811260Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The peaked teeth of the selector sleeve (gearwheel-reverse-gear-side) are facing upwards.

  20. Position the sleeve carrier assembly (1) on the DT-46759  sleeve.
    21. Fig 14: Positioning Upper Main Shaft To Sleeve Carrier Assembly
    GM2811263Courtesy of GENERAL MOTORS COMPANY
  21. Position the upper main shaft (1) into the sleeve carrier assembly and the DT-46759  sleeve.
    22. Fig 15: Turning Reverse Gearwheel
    GM2811264Courtesy of GENERAL MOTORS COMPANY
  22. Turn the reverse gear gearwheel (1). Turning the gearwheel secures correct fitting of the synchronizer ring (2) into the sleeve carrier (small arrow).
    23. Fig 16: Supporting Synchronizer System
    GM2811265Courtesy of GENERAL MOTORS COMPANY
  23. Support the synchronizer system, using the DT-46759  sleeve (2).
  24. Install the synchronizer system (1) and the reverse gear gearwheel to the upper main shaft. Press in the upper main shaft.
  25. Check free rotating reverse gear gearwheel.
    26. Fig 17: Installing Distance Bushing
    GM2811267Courtesy of GENERAL MOTORS COMPANY
  26. Install the distance bushing (2) to the upper main shaft. Press on the distance bushing, using the DT-46759  sleeve (1).
    27. Fig 18: Distance Bushing Retaining Ring
    GM2811236Courtesy of GENERAL MOTORS COMPANY
  27. Install the NEW distance bushing retaining ring (1) to the upper main shaft, using the GE-396  pliers.
    28. Fig 19: 3rd Gear Needle Bearing
    GM2811234Courtesy of GENERAL MOTORS COMPANY
  28. Install the 3rd gear needle bearing (1) to the upper main shaft.
    29. Fig 20: Installing 3rd Gearwheel To Upper Main Shaft
    GM2811268Courtesy of GENERAL MOTORS COMPANY
  29. Install the 3rd gear gearwheel (1) to the upper main shaft.
    30. Fig 21: Ensuring Synchronizer Rings Fit
    GM2811269Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the synchronizer rings fit.

  30. Install the three 3rd gear synchronizer rings (1, 2, 3)
    • Synchronizer ring (2) must fit correctly into the 3rd gear gearwheel (lower arrow).
    • Synchronizer rings (1, 3) must fit correctly together (upper arrow).
    31. Fig 22: Making Sure Synchronizer Ring Fits
    GM2811273Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the synchronizer ring fits.

  31. Install the 3rd / 4th gear sleeve carrier (2) to the upper main shaft. Press on the sleeve carrier, using the DT-46759  sleeve (1).
    • Before pressing, the synchronizer ring must be aligned to the sleeve carrier (arrows).
    32. Fig 23: Sleeve Carrier Retaining Ring
    GM2811228Courtesy of GENERAL MOTORS COMPANY
  32. Install the NEW sleeve carrier retaining ring (1) to the upper main shaft, using the GE-396  pliers.
    33. Fig 24: Installing Spring Catches To 3rd/4th Gear Sleeve Carrier
    GM2811274Courtesy of GENERAL MOTORS COMPANY
  33. Install the 3 spring catches (1) to the 3rd / 4th gear sleeve carrier.
    34. NOTE:

    Make sure that the position of the selector sleeve is correct.

  34. Install the selector sleeve (2) to the 3rd / 4th gear sleeve carrier

    The pits in the selector sleeve (arrow) must be installed in the position of the spring catches.

    35. Fig 25: Synchronizer Rings And 3rd/4th Gear Sleeve Carrier
    GM2811278Courtesy of GENERAL MOTORS COMPANY
  35. Install the 3 synchronizer rings (1) to the 3rd / 4th gear sleeve carrier (2).
    36. Fig 26: 4th Gear Needle Bearing
    GM2811279Courtesy of GENERAL MOTORS COMPANY
  36. Install the 4th gear needle bearing (1) to the upper main shaft.
    37. Fig 27: 4th Gearwheel And Upper Main Shaft
    GM2811281Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the synchronizer ring fits.

  37. Install the 4th gear gearwheel (1) to the upper main shaft.

    Turn the 4th gear gearwheel. Turning the gearwheel secures correct fitting of the synchronizer ring into the gearwheel (arrow).

    38. Fig 28: Installer Sleeve
    GM2811282Courtesy of GENERAL MOTORS COMPANY
  38. Install NEW outer bearing (2) to the upper main shaft. Press on outer bearing, using the DT-60000-60  sleeve (1) with function side "B".
    39. Fig 29: Retaining Ring
    GM2811203Courtesy of GENERAL MOTORS COMPANY
  39. Measure the fitting of the NEW outer bearing retaining ring (1). Try different thicknesses of retaining ring.
    • Retaining ring must not fit loosely into the groove.
    • Use the thickest retaining ring possible.
  40. Install NEW outer bearing retaining ring to the upper main shaft, using the GE-396  pliers.
    41. Fig 30: 3rd/4th Gear And Reverse Selector Sleeve
    GM2811285Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Reverse gear selector sleeve (2) must only be shifted directed toward the reverse gear gearwheel and into neutral gear. Failure to follow this instruction will cause dropping the spring catches.

  41. Perform function check.
    1. Check free rotating of all gearwheels.
    2. Shift all gears
      • 3rd / 4th gear selector sleeve (1)
      • Reverse gear selector sleeve (2)
    3. Shift upper main shaft into neutral.
    42. Fig 31: Special Tool Support Sleeve
    GM2811251Courtesy of GENERAL MOTORS COMPANY
  42. Support the lower main shaft inner bearing (1), using the DT-46759  sleeve (2).
  43. Install the inner bearing to the lower main shaft. Press in the lower main shaft.
    44. Fig 32: Inner Bearing Retaining Ring
    GM2813976Courtesy of GENERAL MOTORS COMPANY
  44. Measure the fitting of the NEW inner bearing retaining ring (1). Try different thicknesses of retaining ring.
    • Retaining ring must not fit loosely into the groove.
    • To huge retaining ring can grind or block the 1st gear gearwheel.
    • Use the thickest retaining ring possible.
    45. Fig 33: Retaining Ring Clamps
    GM2811247Courtesy of GENERAL MOTORS COMPANY
  45. Install the NEW inner bearing retaining ring (1) to the lower main shaft, using the GE-396  pliers.
    46. Fig 34: 1st Gear Needle Bearing
    GM2813974Courtesy of GENERAL MOTORS COMPANY
  46. Install the 1st gear needle bearing (1) to the lower main shaft.
    47. Fig 35: Axial Needle Bearing And 1st Gear Gearwheel
    GM2813977Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    An axial needle bearing is not standard in every transmission. In course of the repair install axial needle bearing into every transmission.

  47. Install NEW axial needle bearing (1) to the 1st gear gearwheel (2). Needles of the bearing facing towards the inner bearing of the lower main shaft. Glue the bearing with grease to the gearwheel.
    48. Fig 36: 1st/2nd Gear Sleeve Carrier And Sleeve
    GM2813978Courtesy of GENERAL MOTORS COMPANY
  48. Position the 1st / 2nd gear sleeve carrier (1) on the DT-46759  sleeve (2).
    49. Fig 37: Ensuring Proper Shim Fit
    GM2813979Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the shim fits correctly.

  49. Position the shim (2) on the 1st / 2nd gear sleeve carrier (1).
    • The borders of the shim must facing towards the spring catches.
    • The shape of the shim covers the shape of the sleeve carrier (arrow).
    50. Fig 38: 1st Gear Synchronizer Ring
    GM2813980Courtesy of GENERAL MOTORS COMPANY
  50. Position the 1st gear synchronizer ring (1) on the 1st / 2nd gear sleeve carrier.
    51. Fig 39: Positioning Two 1st Gear Synchronizer Rings
    GM2813981Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the upper synchronizer ring fits into the sleeve carrier.

  51. Position the two 1st gear synchronizer rings (1) on the 1st / 2nd gear sleeve carrier.

    Turn the upper synchronizer ring till it fits correctly into the sleeve carrier.

    52. Fig 40: 1st Gear Gearwheel
    GM2813982Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the gearwheel fits into the synchronizer ring.

  52. Position the NEW 1st gear gearwheel (2) and NEW axial needle bearing (1) on the 1st / 2nd gear sleeve carrier.

    The middle synchronizer ring must fit into the gearwheel.

    53. Fig 41: 1st Gear Needle Bearing
    GM2813984Courtesy of GENERAL MOTORS COMPANY
  53. Position the 1st gear needle bearing (1) into the 1st gear gearwheel.
    54. Fig 42: Positioning Lower Main Shaft Into Sleeve
    GM2813986Courtesy of GENERAL MOTORS COMPANY
  54. Position the lower main shaft (1) into the DT-46759  sleeve (2).
    55. Fig 43: Checking Axial Needle Bearing Fir
    GM2813987Courtesy of GENERAL MOTORS COMPANY
  55. Check that the axial needle bearing (1) fits correctly.
    56. Fig 44: Turning 1st Gear Gearwheel
    GM2813988Courtesy of GENERAL MOTORS COMPANY
  56. Turn the 1st gear gearwheel (1). Turning the gearwheel secures that the synchronizer fits correctly into the gearwheel.
    57. Fig 45: Supporting 1st Gear Gearwheel In Sleeve
    GM2813989Courtesy of GENERAL MOTORS COMPANY
  57. Support the 1st / 2nd gear sleeve carrier (1), using the DT-46759  sleeve (2).
  58. Install the 1st / 2nd gear sleeve carrier and the reverse gear gearwheel to the lower main shaft. Press in the lower main shaft.
  59. Check free rotating of the 1st gear gearwheel.
    60. Fig 46: 1st/2nd Gear Sleeve Carrier Retaining Ring
    GM2813971Courtesy of GENERAL MOTORS COMPANY
  60. Install the NEW 1st / 2nd gear sleeve carrier retaining ring (1) to the lower main shaft, using the GE-396  pliers.
    61. Fig 47: Spring Catches
    GM2813990Courtesy of GENERAL MOTORS COMPANY
  61. Install the 3 spring catches (1, 2) to the 1st / 2nd gear sleeve carrier.
    62. Fig 48: Selector Sleeve
    GM2813993Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the position of the selector sleeve is correct.

  62. Install the selector sleeve (1) to the 1st / 2nd gear sleeve carrier
    • The pits in the selector sleeve (arrow) must be installed in the position of the spring catches.
    63. Fig 49: Synchronizer Rings
    GM2813994Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the first synchronizer ring fits into the sleeve carrier (arrow).

  63. Install the 3 synchronizer rings (1) to the 1st / 2nd gear sleeve carrier (2).
    64. Fig 50: 2nd Gear Needle Bearing
    GM2813967Courtesy of GENERAL MOTORS COMPANY
  64. Install the 2nd gear needle bearing (1) to the lower main shaft.
    65. Fig 51: 2nd Gear Gearwheel
    GM2813966Courtesy of GENERAL MOTORS COMPANY
  65. Install the 2nd gear gearwheel (1) to the lower main shaft.
    66. Fig 52: Turning 2nd Gear Gearwheel
    GM2813995Courtesy of GENERAL MOTORS COMPANY
  66. Turn the 2nd gear gearwheel (1). Turning the gearwheel secures correct fitting of the gearwheel into the synchronizer ring.
    67. Fig 53: Support Ring And Washer
    GM2811306Courtesy of GENERAL MOTORS COMPANY
  67. Install the 2 thrust washers (2) and the support ring (1) to the lower main shaft.
    68. Fig 54: 5th Gear Needle Bearing
    GM2811305Courtesy of GENERAL MOTORS COMPANY
  68. Install the 5th gear needle bearing (1) to the lower main shaft.
    69. Fig 55: Lower Main Shaft And 5th Gearwheel
    GM2811303Courtesy of GENERAL MOTORS COMPANY
  69. Install the 5th gear gearwheel (1) to the lower main shaft.
    70. Fig 56: 5th Gear Synchronizer Ring
    GM2813996Courtesy of GENERAL MOTORS COMPANY
  70. Install the 5th gear synchronizer ring (1) to lower main shaft.
    71. Fig 57: Aligning Synchronizer Ring
    GM2813997Courtesy of GENERAL MOTORS COMPANY
  71. Align the synchronizer ring to the opening in the sleeve carrier (arrows).
    72. NOTE:

    Make sure that the position of the synchronizer ring is correct.

  72. Install the 5th / 6th gear sleeve carrier (2) to the lower main shaft. Press on the sleeve carrier, using the DT-46759  sleeve (1)
  73. Check free rotating of the 2nd gear gearwheel and 5th gear gearwheel.
    74. Fig 58: 5th/6th Gear Selector Sleeve Retainer Ring
    GM2811296Courtesy of GENERAL MOTORS COMPANY
  74. Install the NEW 5th / 6th gear sleeve carrier retaining ring (1) to the lower main shaft, using the GE-396  pliers.
    75. Fig 59: Spring Catches
    GM2813998Courtesy of GENERAL MOTORS COMPANY
  75. Install the 3 spring catches (1, 2) to the 5th / 6th gear sleeve carrier.
    76. Fig 60: Ensuring Correct Selector Sleeve Position
    GM2813999Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the position of the selector sleeve is correct.

  76. Install the selector sleeve (1) to the 5th / 6th gear sleeve carrier.

    The pits in the selector sleeve (arrow) must be installed in the position of the spring catches.

    77. Fig 61: 6th Gear Synchronizer Ring
    GM2811294Courtesy of GENERAL MOTORS COMPANY
  77. Install the 6th gear synchronizer ring (1) to the 5th / 6th gear sleeve carrier.
    78. Fig 62: 6th Gear Needle Bearing
    GM2811293Courtesy of GENERAL MOTORS COMPANY
  78. Install the 6th gear needle bearing (1) to the lower main shaft.
    79. Fig 63: 6th Gearwheel
    GM2811292Courtesy of GENERAL MOTORS COMPANY
  79. Install the 6th gear gearwheel (1) to the lower main shaft.
    80. Fig 64: Installing Outer Bearing With Special Tool
    GM2814000Courtesy of GENERAL MOTORS COMPANY
  80. Install the NEW outer bearing (2) to the lower main shaft. Press on the outer bearing, using the DT-60000-60  sleeve (1) with function side "B".
    81. Fig 65: Outer Bearing Retaining Ring
    GM2811286Courtesy of GENERAL MOTORS COMPANY
  81. Measure the fitting of the NEW outer bearing retaining ring (1). Try different thicknesses of the retaining ring.
    • Retaining ring must not fit loosely into the groove.
    • Use the thickest retaining ring possible.
  82. Install the NEW outer bearing retaining ring to the lower main shaft, using the GE-396  pliers.
    83. Fig 66: Checking Component Function
    GM2814002Courtesy of GENERAL MOTORS COMPANY
  83. Perform a function check.
    1. Check free rotating of all gearwheels.
    2. Shift all gears
      • 5th / 6th gear selector sleeve (1)
      • 1st / 2nd gear selector sleeve (2)
    3. Shift lower main shaft into neutral.
    84. Fig 67: Special Installer Tool
    GM2814013Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    DT-60000-90  installer can be used for two different sizes of input shaft inner bearing outer rings.

  84. Determine the correct function side of DT-60000-90  installer (1).
  85. Move (arrows) both sides of the DT-60000-90  installer in the input shaft inner bearing outer ring. Use the side with the lowest clearance.
    86. Fig 68: Special Installation Tool
    GM2814014Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Failure to install the outer ring completely will cause incorrect measurement of the shim ring.

  86. Install NEW input shaft inner bearing outer ring (3) to the clutch housing, using the DT-60000-90  installer (1) and DT-523-1  handle (2). Make sure to use the correct function side of DT-60000-90  installer. Hammer the outer ring completely into the clutch housing till a clarion, metallic sound is to hear.
    87. Fig 69: Installing Outer Rings
    GM2814016Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Failure to install the outer rings completely will cause incorrect measurement of the shim rings.

  87. Install 2 NEW main shaft inner bearing outer rings (2) to the clutch housing, using the DT-60000-110  installer and DT-523-1  handle (1). Hammer the outer rings completely into the clutch housing till a clarion, metallic sound is to hear.
    88. Fig 70: Clutch Housing
    GM2814012Courtesy of GENERAL MOTORS COMPANY
  88. Install the clutch housing (1) to the DT-6115  holder (2).
  89. Secure the DT-6115  holder with the pin.
    90. Fig 71: Upper And Lower Mainshafts
    GM2814024Courtesy of GENERAL MOTORS COMPANY
  90. Install 2 main shafts (1, 2) to the clutch housing.
  91. Install the 1st / 2nd gear shift fork (3) to the lower main shaft.
  92. Install the reverse gear shift fork (4) to the upper main shaft.
    93. Fig 72: Upper And Lower Mainshaft Forks
    GM2814025Courtesy of GENERAL MOTORS COMPANY
  93. Install the 3rd / 4th gear shift fork (4) to the upper main shaft.
  94. Install the 5th / 6th gear shift fork (3) to the lower main shaft.
  95. Install 2 shift shafts (1, 2) to the clutch housing.
    96. Fig 73: Checking Free Rotating Of All Gearwheels
    GM2814026Courtesy of GENERAL MOTORS COMPANY
  96. Install the input shaft (1) to the clutch housing.

    Lift the lower main shaft a bit.

  97. Check free rotating of all gearwheels.
    98. Fig 74: Outer Bearing Outer Rings And Transmission Shafts
    GM2814027Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The outer rings must be clean to avoid incorrect measurement.

  98. Install 3 NEW outer bearing outer rings (1, 2) to the transmission shafts.
    99. Fig 75: Special Spacers
    GM2814029Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    DT-60000-120-5  spacer must be installed in the position of the transmission case cover locating pin.

  99. Install the 2 DT-60000-120-5  spacer (1, 3) to the clutch housing.
  100. Install the 2 DT-60000-120-4  spacer (2, 4) to the clutch housing.
    101. Fig 76: Special Cylinder Tools
    GM2814030Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    DT-60000-120-1  cylinder, DT-60000-120-2  cylinder and DT-60000-120-3  cylinder must be clean at the contact areas to the outer rings to avoid incorrect measurement.

  101. Install DT-60000-120-1  cylinder (2) to the input shaft.
  102. Install the DT-60000-120-2  cylinder (1) to the upper main shaft.
  103. Install the DT-60000-120-3  cylinder (3) to the lower main shaft.
  104. Turn the DT-60000-120-1  cylinder, DT-60000-120-2  cylinder and DT-60000-120-3  cylinder several times on the transmission shaft bearings.
    105. Fig 77: Installing Transmission Case Cover
    GM2814031Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    DT-60000-120-1  cylinder, DT-60000-120-2  cylinder, DT-60000-120-3  cylinder and transmission case cover must be clean at the contact areas. DT-60000-120-1  cylinder, DT-60000-120-2  cylinder and DT-60000-120-3  cylinder must fit into the transmission case cover bore for the outer bearings.

  105. Install the transmission case cover (1) to DT-60000-120-4  spacer and DT-60000-120-5  spacer. Install 4 nuts (2, 3) and cross tighten to 10 N.m (89 lb in).
    106. Fig 78: Turning Transmission Shafts
    GM2814032Courtesy of GENERAL MOTORS COMPANY
  106. Turn the transmission shafts.
      NOTE:

      The correct special tool depends on the input shaft diameter at position of the clutch driven plate.

    1. Install the DT-60000-140  adapter respectively the DT-60000-150  adapter (1)
    2. Shift gears, switch shifting of the gears between the upper main shaft and on the lower main shaft. Turn input shaft 20 times in each gear.
    3. Shift the transmission into neutral.
    107. Fig 79: Measuring Clearances
    GM2814033Courtesy of GENERAL MOTORS COMPANY
  107. Use a feeler gauge (2) with 0.05 mm (0.002 in) increments, measure the thickness of the shim rings.
  108. Measure the clearance at the DT-60000-120-1  cylinder (1), DT-60000-120-2  cylinder and DT-60000-120-3  cylinder.
  109. Note the measured values.
    110. Fig 80: Shim Rings
    GM2814035Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    In case of slight differing values use the smaller value. In case of high differing values check the whole measuring setup.

  110. Make a second measurement on the opposite side (arrows) at DT-60000-120-1  cylinder (1), DT-60000-120-2  cylinder (1) and DT-60000-120-3  cylinder (1).
  111. Note the measured values.
  112. Calculate the thickness of the NEW shim rings:
    • Input shaft: measured value + 0.1 mm (0.004 in) = shim ring thickness
    • Upper main shaft: measured value + 0.4 mm (0.016 in) = shim ring thickness
    • Lower main shaft: measured value + 0.3 mm (0.012 in) = shim ring thickness
    113. Fig 81: Turning Transmission Shafts
    GM2814032Courtesy of GENERAL MOTORS COMPANY
  113. Remove the DT-60000-140  adapter respectively the DT-60000-150  adapter (1) from the input shaft.
    114. Fig 82: Installing Transmission Case Cover
    GM2814031Courtesy of GENERAL MOTORS COMPANY
  114. Remove 4 nuts (2, 3). Remove the transmission case cover (1) from the DT-60000-120-4  spacer and the DT-60000-120-5  spacer.
    115. Fig 83: Special Cylinder Tools
    GM2814030Courtesy of GENERAL MOTORS COMPANY
  115. Remove the DT-60000-120-1  cylinder (2), DT-60000-120-2  cylinder (1) and DT-60000-120-3  cylinder (3) from the transmission shafts.
    116. Fig 84: Special Spacers
    GM2814029Courtesy of GENERAL MOTORS COMPANY
  116. Remove the 2 DT-60000-120-5  spacers (1, 3) from the clutch housing.
  117. Remove the 2 DT-60000-120-4  spacers (2, 4) from the clutch housing.
    118. Fig 85: Outer Bearing Outer Rings And Transmission Shafts
    GM2814027Courtesy of GENERAL MOTORS COMPANY
  118. Remove the 3 NEW outer bearing outer rings (1, 2) from the transmission shafts.
    119. Fig 86: Transmission Case Cover
    GM2814130Courtesy of GENERAL MOTORS COMPANY
  119. Install transmission case cover (1) to the DT-60000-130  holder (3). Install 2 washers and 2 nuts (2, 4) and tighten.
    120. Fig 87: Adjusting Tool Supports
    GM2814018Courtesy of GENERAL MOTORS COMPANY
  120. Turn the supports (1, 2) counterclockwise and hand tighten.
    121. Fig 88: Shim Rings
    GM2814036Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure to use the measured and calculated shim rings.

  121. Install 3 NEW shim rings (1) to the transmission case cover.
    122. Fig 89: Special Installer Tool
    GM2814013Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    DT-60000-100  installer can be used for two different sizes of outer bearing outer rings.

  122. Determine the correct function side of DT-60000-100  installer (1).

    Move (arrows) both sides of the DT-60000-100  installer in the outer bearing outer rings. Use the side with the lowest clearance.

    123. Fig 90: Installing Bearings With Special Tool
    GM2814037Courtesy of GENERAL MOTORS COMPANY
  123. Install 3 NEW outer bearing outer rings (1) to the transmission case cover, using DT-60000-100  installer (3) and DT-523-1  handle (2). Make sure to use the correct function side of DT-60000-100  installer. Hammer the outer ring completely into the clutch housing till a clarion, metallic sound is to hear.
  124. Remove the transmission case cover from the DT-60000-130  holder.
    125. Fig 91: Transmission Magnet
    GM2814038Courtesy of GENERAL MOTORS COMPANY
  125. Install the transmission magnet (1) to the clutch housing.
    126. Fig 92: Neutral Gear
    GM2811168Courtesy of GENERAL MOTORS COMPANY
  126. Install the shift control housing (1) to the clutch housing.
  127. Install the 2 shift control housing bolts (2, 3) and tighten to 20 N.m (15 lb ft).
    128. Fig 93: Backup Lamp Switch
    GM2811167Courtesy of GENERAL MOTORS COMPANY
  128. Install the backup lamp switch (1) to the clutch housing and tighten to 20 N.m (15 lb ft).
    129. Fig 94: Applying Sealant To Case Cover
    GM2814040Courtesy of GENERAL MOTORS COMPANY
  129. Clean the sealing surface at the transmission case cover. The sealing surface must be free from oil and grease.
  130. Apply sealant (1) 2-3 mm (0.08-0.12 in) thick to the transmission case cover. Apply sealant without interruption. Apply inside of the bores.
    131. Fig 95: Case Cover Bolt Tightening Sequence
    GM2814041Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Bolt 16 must be positioned in original position.

  131. Install the transmission case cover. Install the 16 transmission case cover bolts and tighten a first pass to 5 N.m (44 lb in).
  132. Tighten the transmission case cover bolts a final pass to an additional 21 N.m (16 lb ft).
  133. Check bolt torque. Clockwise check every bolt 21 N.m (16 lb ft).
  134. Turn the clutch housing and the DT-6115  holder (1) 180 degree. Clutch side facing upwards.
  135. Secure the DT-6115  holder with the pin.
    136. Fig 96: Special Installation Tool
    GM2814043Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The correct special tool depends on the input shaft diameter. During the installation the seal ring is positioned on the special tool.

  136. Install NEW input shaft seal ring (2), using the DT-60000-160  installer (1) respectively the DT-60000-170  installer (1). Hammer in flush. Make sure that the seal lip fits correct.
  137. Install the clutch actuator cylinder to the clutch housing. Refer to Clutch Actuator Cylinder Replacement .
    138. Fig 97: Transmission And Holder Tool
    GM2811164Courtesy of GENERAL MOTORS COMPANY
  138. Turn the clutch housing (1) and the DT-6115  holder (2) 180 degree. Transmission side facing upwards.
  139. Secure the DT-6115  holder with the pin.
    140. NOTE:

    2nd technician required.

  140. Remove the 2 bolts. Remove the transmission from the DT-6115  holder.
  141. Perform function check.

    During shifting all gears turn the input shaft. Input shaft must be turnable by hand. Where necessary use the DT-60000-140  adapter respectively the DT-60000-150  adapter.

    142. NOTE:

    After complete installation fill the transmission with 2.4 liters (2.54 quarts) transmission fluid.

    This value may be different from published values in the service literature. This value is binding for this work process.

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