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Input and Main Shaft Bearing Replacement

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

Special Tools

For equivalent regional tools, refer to Special Tools .

NOTE:

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:

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).

  1. Remove the transmission. Refer to Transmission Replacement .
    2. Fig 1: Special Holding Tools
    GM2811162Courtesy of GENERAL MOTORS COMPANY
  2. Install DT-6115  holder (3) to DT-113-2-A  holder (1).
  3. Secure with pin (2).
  4. Screw in grub screw (arrow).
    5. Fig 2: Transmission And Holder Tool
    GM2811164Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    2nd technician required.

  5. Install the transmission (1) to the DT-6115  holder (2).
    1. Align and secure the transmission with the differential cover pointing to the rear.
    2. Tighten with 2 bolts.
    6. Fig 3: Transmission Case Cover Bolts
    GM2811165Courtesy of GENERAL MOTORS COMPANY
  6. Remove the 16 transmission case cover bolts (1).
    7. Fig 4: Transmission Case Cover
    GM2811166Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    DO NOT hit or knock transmission case cover.

  7. Remove the transmission case cover (2). Lift the transmission case cover evenly with plastic levers (1, 3).
    8. Fig 5: Outer Shaft Bearings
    GM2811161Courtesy of GENERAL MOTORS COMPANY
  8. Check outer shaft bearings.
  9. Check all gearwheels for damage.
    1. Check for cavitation on the tooth flanks.
    2. Check for pitting on the tooth flanks.
    3. Check for broken teeth.
    10. Fig 6: Backup Lamp Switch
    GM2811167Courtesy of GENERAL MOTORS COMPANY
  10. Remove the backup lamp switch (1).
    11. Fig 7: Neutral Gear
    GM2811168Courtesy of GENERAL MOTORS COMPANY
  11. Select the neutral gear.
  12. Remove the 2 shift control housing bolts (2, 3).
  13. Remove the shift control housing (1).
    14. Fig 8: Transmission Magnet
    GM2814038Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    To prevent the transmission components becoming magnetized accidentally, they must not come in contact with the magnet.

  14. Remove the transmission magnet (1) from the clutch housing. Store it separately away from all the other transmission components.
    15. Fig 9: Shift Shafts And Shift Forks
    GM2811169Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Place the components on clean base.

  15. Remove the shift shafts (1, 4).
  16. Remove the shift forks (2, 3).
    17. Fig 10: Input Shaft
    GM2811170Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Place the input shaft on clean base.

  17. Remove the input shaft (1).
    18. Fig 11: Upper And Lower Main Shafts
    GM2811172Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Place the main shafts on clean base.

  18. Remove the upper main shaft (1) and the lower main shaft (2).
  19. Check all components of the three transmission shafts for damage.
    20. Fig 12: 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.

  20. 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.
    21. Fig 13: 1st Gear
    GM2811176Courtesy of GENERAL MOTORS COMPANY
  21. Count the teeth of the 1st gear gearwheel (1).
    1. Quantity:
      • 42 teeth
      • 47 teeth
    2. Note the quantity of the counted teeth.
  22. 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.
      • Partnumber 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).
    23. Fig 14: Input Shaft And Bolt
    GM2811177Courtesy of GENERAL MOTORS COMPANY
  23. Clamp the input shaft (1) into a vise (3), using aluminum protective jaws (2).
  24. Remove and DISCARD the input shaft bolt (4) from the input shaft.
    25. Fig 15: Input Shaft And Special Tool
    GM2811178Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    DT-60000-60  sleeve is used to support the input shaft and to push on the outer bearing of the two main shafts.

    Use the function side of DT-60000-60  sleeve determined according to the measured transmission shaft diameter "X" to support the input shaft.

  25. Determine the correct function side of DT-60000-60  sleeve (2)
    • Input shaft (1) Diameter "X" = 24.5 mm (0.96 in): Function side "A"
    • Input shaft (1) Diameter "X" = 26.0 mm (1.02 in): Function side "B"
    26. Fig 16: Special Sleeve Tool
    GM2811179Courtesy of GENERAL MOTORS COMPANY
  26. Insert the input shaft (1) into 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.
    27. Fig 17: Input Shaft And Bearing Cage
    GM2811180Courtesy of GENERAL MOTORS COMPANY
  27. Cut in the bearing cage (2) of the input shaft in several places on the top, using side cutting pliers (1).
    28. Fig 18: Lifting Bearing Cage
    GM2811181Courtesy of GENERAL MOTORS COMPANY
  28. Cut in the bearing cage (2) of the input shaft in several places on the bottom, using side cutting pliers (1). If necessary, use a screwdriver (3) to lift the cage.
  29. Remove and DISCARD the cage (2).
  30. Remove and DISCARD all rollers.
    31. Fig 19: Special Removal Tool
    GM2811182Courtesy of GENERAL MOTORS COMPANY
  31. Install the DT-60000-10  remover (1) to the outer bearing inner ring (2) of the input shaft, make sure of proper seat (arrow).
  32. Tighten 2 nuts of the DT-60000-10  remover.
    33. Fig 20: Inner Ring And Special Tool
    GM2811183Courtesy of GENERAL MOTORS COMPANY
  33. Support the inner ring using the DT-60000-10  remover (1).
  34. Remove the outer bearing inner ring (3) from the input shaft. Press out the input shaft using the EN-235-5-1  pivot (2).
    35. Fig 21: Removal Tool
    GM2811184Courtesy of GENERAL MOTORS COMPANY
  35. Remove the DT-60000-10  remover (1) from the inner ring (2).
    36. Fig 22: Cutting Bearing Cage
    GM2811185Courtesy of GENERAL MOTORS COMPANY
  36. Cut in the bearing cage (2) of the input shaft in several places on the top, using side cutting pliers (1).
    37. Fig 23: Cutting Bearing Cage Of Input Shaft Bearing
    GM2811189Courtesy of GENERAL MOTORS COMPANY
  37. Cut in the bearing cage (2) of the input shaft in several places on the bottom, using side cutting pliers (1).
  38. Remove and DISCARD the cage (2).
  39. Remove and DISCARD all rollers.
    40. Fig 24: Bearing Removal Tool
    GM2811191Courtesy of GENERAL MOTORS COMPANY
  40. Install the DT-60000-10  remover (1) to the inner bearing inner ring (2) of the input shaft, make sure of proper seat.
  41. Tighten the 2 nuts of the DT-60000-10  remover.
    42. Fig 25: Removal Tool And Inner Bearing Inner Ring
    GM2811192Courtesy of GENERAL MOTORS COMPANY
  42. Support the inner ring using the DT-60000-10  remover (1).
  43. Remove the inner bearing inner ring from the input shaft (2). Press out the input shaft.
    44. Fig 26: Removal Tool
    GM2811184Courtesy of GENERAL MOTORS COMPANY
  44. Remove the DT-60000-10  remover (1) from the inner ring (2).
  45. Re-cut the input shaft bolt thread.
  46. Clean all components of the input shaft.
  47. Dry all components of the input shaft.
  48. Check all components of the input shaft for damage.
    • Damaged parts must not be installed.
  49. Lubricate all components of the input shaft with transmission fluid for corrosion protection.
    50. Fig 27: Input Shaft Support Sleeve
    GM2811197Courtesy of GENERAL MOTORS COMPANY
  50. 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.
  51. Press on NEW outer bearing (3) to the input shaft, using the DT-6339  installer (1).
    52. Fig 28: Input Shaft And Bolt
    GM2811177Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Input shaft thread must be free from oil and grease.

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

    Refer to Fastener Caution .

  55. Install NEW input shaft bolt to the input shaft and tighten to 65 N.m (48 lb ft).
    56. Fig 29: Pressing Inner Bearing On Input Shaft
    GM2811201Courtesy of GENERAL MOTORS COMPANY
  56. 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.
    57. Fig 30: Retaining Ring
    GM2811203Courtesy of GENERAL MOTORS COMPANY
  57. Remove and DISCARD the retaining ring (1) from the upper main shaft, using the GE-396  pliers.
    58. Fig 31: Outer Bearing Cage
    GM2811212Courtesy of GENERAL MOTORS COMPANY
  58. Cut in the outer bearing cage (2) of the upper main shaft in several places on the top, using side cutting pliers (1).
    59. Fig 32: Cutting Outer Bearing Cage
    GM2811214Courtesy of GENERAL MOTORS COMPANY
  59. Cut in the outer bearing cage (2) of the upper main shaft in several places on the bottom, using side cutting pliers (1). If necessary, use a screwdriver (3) to lift the cage.
  60. Remove and DISCARD the cage.
  61. Remove and DISCARD all rollers.
    62. Fig 33: Removal Tool
    GM2811217Courtesy of GENERAL MOTORS COMPANY
  62. Install the DT-60000-10  remover (1) to the outer bearing inner ring (2) of the upper main shaft, make sure of proper seat (arrow).
  63. Tighten 2 nuts of the DT-60000-10  remover.
    64. Fig 34: Supporting Inner Ring Using Special Tool
    GM2811218Courtesy of GENERAL MOTORS COMPANY
  64. Support the inner ring using the DT-60000-10  remover (1).
  65. Remove the outer bearing inner ring (3) from the upper main shaft. Press out the upper main shaft, using the CH-500-5  pivot (2).
    66. Fig 35: Removal Tool
    GM2811184Courtesy of GENERAL MOTORS COMPANY
  66. Remove the DT-60000-10  remover (1) from the inner ring (2).
    67. Fig 36: 4th Gear Gearwheel
    GM2811221Courtesy of GENERAL MOTORS COMPANY
  67. Remove the 4th gear gearwheel (1) from the upper main shaft.
  68. Remove the 4th gear needle bearing (2) from the upper main shaft.
    69. Fig 37: 4th Gear Synchronizer Rings
    GM2811224Courtesy of GENERAL MOTORS COMPANY
  69. Remove 3 4th gear synchronizer rings (1) from the upper main shaft.
    70. Fig 38: 4th Gear Selector Sleeve
    GM2811226Courtesy of GENERAL MOTORS COMPANY
  70. Remove the 3rd / 4th gear selector sleeve (2) from the 3rd / 4th gear sleeve carrier.
  71. Remove 3 spring catches (1, 3) from the sleeve carrier.
    72. Fig 39: Sleeve Carrier Retaining Ring
    GM2811228Courtesy of GENERAL MOTORS COMPANY
  72. Remove and DISCARD the sleeve carrier retaining ring (1) from the upper main shaft, using the GE-396  pliers.
    73. Fig 40: Supporting 3rd Gearwheel Using Special Tool Plate
    GM2811231Courtesy of GENERAL MOTORS COMPANY
  73. Support the 3rd gear gearwheel (3), using the DT-307-B  plate (1).
  74. Remove the 3rd / 4th gear sleeve carrier (2) and the 3rd gear gearwheel from the upper main shaft. Press out the upper main shaft.
    75. Fig 41: 3rd Gear Synchronizer Rings
    GM2811232Courtesy of GENERAL MOTORS COMPANY
  75. Remove the 3rd / 4th gear sleeve carrier (2) and the three 3rd gear synchronizer rings (1) from the 3rd gear gearwheel (3).
    76. Fig 42: 3rd Gear Needle Bearing
    GM2811234Courtesy of GENERAL MOTORS COMPANY
  76. Remove the 3rd gear needle bearing (1) from the upper main shaft.
    77. Fig 43: Distance Bushing Retaining Ring
    GM2811236Courtesy of GENERAL MOTORS COMPANY
  77. Remove and DISCARD the distance bushing retaining ring (1) from the upper main shaft, using the GE-396  pliers.
    78. Fig 44: Gearwheel Support Plate
    GM2811238Courtesy of GENERAL MOTORS COMPANY
  78. Support the reverse gear gearwheel (4), using the DT-307-B  plate (1).
  79. Remove the distance bushing (2), the reverse gear synchronizer system (3) and the reverse gear gearwheel (4) from the upper main shaft. Press out the upper main shaft.
    80. Fig 45: Sleeve Carrier Assembly And Synchronizer Ring
    GM2811240Courtesy of GENERAL MOTORS COMPANY
  80. Remove the sleeve carrier assembly (2) and the synchronizer ring (1) of the reverse gear from the reverse gear gearwheel (3).
    81. Fig 46: Spring Catches And Sleeve Carrier
    GM2811241Courtesy of GENERAL MOTORS COMPANY
  81. Remove the selector sleeve (1) from the reverse gear sleeve carrier.
  82. Remove 3 spring catches (2, 3) from the sleeve carrier.
    83. Fig 47: Reverse Gear Needle Bearing And Upper Main Shaft
    GM2811243Courtesy of GENERAL MOTORS COMPANY
  83. Remove the reverse gear needle bearing (1) from the upper main shaft.
    84. Fig 48: Special Tools
    GM2811245Courtesy of GENERAL MOTORS COMPANY
  84. Remove the ring (2) and the cap (1) from the DT-46759  sleeve (3).
    85. Fig 49: Retaining Ring Clamps
    GM2811247Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    If the retaining ring clamps / stucks on the upper main shaft, perform next step at first, in order to loosen the retaining ring (1).

  85. Remove and DISCARD the inner bearing retaining ring (1) from the upper main shaft, using the GE-396  pliers.
    86. Fig 50: Supporting Upper Main Shaft, Using Sleeve
    GM2811246Courtesy of GENERAL MOTORS COMPANY
  86. Support the upper main shaft, using the DT-46759  sleeve (2). Press the inner bearing (1) against the gearwheel of the differential gear drive.
    87. Fig 51: Removing Upper Main Shaft Inner Bearing
    GM2811249Courtesy of GENERAL MOTORS COMPANY
  87. Support the inner bearing (1), using the DT-60000-30  sleeve (2).

    Remove the inner bearing from the upper main shaft. Press out the upper main shaft.

  88. Clean all components of the upper main shaft.
  89. Dry all components of the upper main shaft.
  90. Check all components of the upper main shaft for damage.
    • Damaged parts must not be installed.
  91. Lubricate all components of the upper main shaft with transmission fluid for corrosion protection.
    92. Fig 52: Special Tool Support Sleeve
    GM2811251Courtesy of GENERAL MOTORS COMPANY
  92. Support the upper main shaft inner bearing (1), using the DT-46759  sleeve (2).
  93. Install the inner bearing to the upper main shaft. Press in the upper main shaft.
    94. Fig 53: Inner Bearing Retaining Ring
    GM2811253Courtesy of GENERAL MOTORS COMPANY
  94. 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.
    95. Fig 54: Retaining Ring Clamps
    GM2811247Courtesy of GENERAL MOTORS COMPANY
  95. Install NEW inner bearing retaining ring (1) to the upper main shaft, using the GE-396  pliers.
    96. Fig 55: Reverse Gear Needle Bearing And Upper Main Shaft
    GM2811243Courtesy of GENERAL MOTORS COMPANY
  96. Install the reverse gear needle bearing (1) to the upper main shaft.
    97. Fig 56: Installing Reverse Gearwheel To Upper Main Chaff
    GM2811255Courtesy of GENERAL MOTORS COMPANY
  97. Install the reverse gear gearwheel (1) to the upper main shaft.
    98. Fig 57: Installing Synchronizer Ring
    GM2811257Courtesy of GENERAL MOTORS COMPANY
  98. Install the synchronizer ring (1) to the reverse gear gearwheel.
    99. Fig 58: Spring Catches And Reverse Gear Sleeve Carrier
    GM2811259Courtesy of GENERAL MOTORS COMPANY
  99. Install the 3 spring catches (1) to the reverse gear sleeve carrier (2).
    100. NOTE:

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

  100. 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.
    101. Fig 59: Sleeve Carrier Assembly
    GM2811260Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  101. Position the sleeve carrier assembly (1) on the DT-46759  sleeve.
    102. Fig 60: Positioning Upper Main Shaft To Sleeve Carrier Assembly
    GM2811263Courtesy of GENERAL MOTORS COMPANY
  102. Position the upper main shaft (1) into the sleeve carrier assembly and the DT-46759  sleeve.
    103. Fig 61: Turning Reverse Gearwheel
    GM2811264Courtesy of GENERAL MOTORS COMPANY
  103. Turn the reverse gear gearwheel (1). Turning the gearwheel secures correct fitting of the synchronizer ring (2) into the sleeve carrier (small arrow).
    104. Fig 62: Supporting Synchronizer System
    GM2811265Courtesy of GENERAL MOTORS COMPANY
  104. Support the synchronizer system, using the DT-46759  sleeve (2).
  105. Install the synchronizer system (1) and the reverse gear gearwheel to the upper main shaft. Press in the upper main shaft.
  106. Check free rotating reverse gear gearwheel.
    107. Fig 63: Installing Distance Bushing
    GM2811267Courtesy of GENERAL MOTORS COMPANY
  107. Install the distance bushing (2) to the upper main shaft. Press on the distance bushing, using the DT-46759  sleeve (1).
    108. Fig 64: Distance Bushing Retaining Ring
    GM2811236Courtesy of GENERAL MOTORS COMPANY
  108. Install the NEW distance bushing retaining ring (1) to the upper main shaft, using the GE-396  pliers.
    109. Fig 65: 3rd Gear Needle Bearing
    GM2811234Courtesy of GENERAL MOTORS COMPANY
  109. Install the 3rd gear needle bearing (1) to the upper main shaft.
    110. Fig 66: Installing 3rd Gearwheel To Upper Main Shaft
    GM2811268Courtesy of GENERAL MOTORS COMPANY
  110. Install the 3rd gear gearwheel (1) to the upper main shaft.
    111. Fig 67: Ensuring Synchronizer Rings Fit
    GM2811269Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Ensuring synchronizer rings fit.

  111. 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).
    112. Fig 68: Making Sure Synchronizer Ring Fits
    GM2811273Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the synchronizer ring fits.

  112. 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).
    113. Fig 69: Sleeve Carrier Retaining Ring
    GM2811228Courtesy of GENERAL MOTORS COMPANY
  113. Install the NEW sleeve carrier retaining ring (1) to the upper main shaft, using the GE-396  pliers.
    114. Fig 70: Installing Spring Catches To 3Rd/4Th Gear Sleeve Carrier
    GM2811274Courtesy of GENERAL MOTORS COMPANY
  114. Install the 3 spring catches (1) to the 3rd / 4th gear sleeve carrier.
    115. NOTE:

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

  115. 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.

    116. Fig 71: Synchronizer Rings And 3rd/4th Gear Sleeve Carrier
    GM2811278Courtesy of GENERAL MOTORS COMPANY
  116. Install the 3 synchronizer rings (1) to the 3rd / 4th gear sleeve carrier (2).
    117. Fig 72: 4th Gear Needle Bearing
    GM2811279Courtesy of GENERAL MOTORS COMPANY
  117. Install the 4th gear needle bearing (1) to the upper main shaft.
    118. Fig 73: 4th Gearwheel And Upper Main Shaft
    GM2811281Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the synchronizer ring fits.

  118. 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).

    119. Fig 74: Installer Sleeve
    GM2811282Courtesy of GENERAL MOTORS COMPANY
  119. 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".
    120. Fig 75: Retaining Ring
    GM2811203Courtesy of GENERAL MOTORS COMPANY
  120. 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.
  121. Install NEW outer bearing retaining ring to the upper main shaft, using the GE-396  pliers.
    122. Fig 76: 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.

  122. 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.
    123. Fig 77: Outer Bearing Retaining Ring
    GM2811286Courtesy of GENERAL MOTORS COMPANY
  123. Remove and DISCARD the outer bearing retaining ring (1) from the lower main shaft, using GE-396  pliers.
    124. Fig 78: Cutting Bearing Cage
    GM2811288Courtesy of GENERAL MOTORS COMPANY
  124. Cut in the bearing cage (2) of the lower main shaft in several places on the top, using side cutting pliers (1).
    125. Fig 79: Lifting Bearing Cage
    GM2811284Courtesy of GENERAL MOTORS COMPANY
  125. Cut in the bearing cage (2) of the lower main shaft in several places on the bottom, using side cutting pliers (1). If necessary, use a screwdriver (3) to lift the cage.
  126. Remove and DISCARD the cage (2).
  127. Remove and DISCARD all rollers.
    128. Fig 80: Special Removal Tool
    GM2811289Courtesy of GENERAL MOTORS COMPANY
  128. Install the DT-60000-10  remover (1) to the outer bearing inner ring of the lower main shaft, make sure of proper seat (arrow).
  129. Tighten the 2 nuts of the DT-60000-10  remover.
  130. Tighten the 2 nuts of the DT-60000-10  remover.
    131. Fig 81: Supporting Inner Ring
    GM2811291Courtesy of GENERAL MOTORS COMPANY
  131. Support the inner ring using the DT-60000-10  remover (1).
  132. Remove the outer bearing inner ring (3) from the lower main shaft. Press out the lower main shaft, using the CH-500-5  pivot (2).
    133. Fig 82: Removal Tool
    GM2811184Courtesy of GENERAL MOTORS COMPANY
  133. Remove the DT-60000-10  remover (1) from the inner ring (2).
    134. Fig 83: 6th Gearwheel
    GM2811292Courtesy of GENERAL MOTORS COMPANY
  134. Remove the 6th gear gearwheel (1) from the lower main shaft.
    135. Fig 84: 6th Gear Needle Bearing
    GM2811293Courtesy of GENERAL MOTORS COMPANY
  135. Remove the 6th gear needle bearing (1) from the lower main shaft.
    136. Fig 85: 6th Gear Synchronizer Ring
    GM2811294Courtesy of GENERAL MOTORS COMPANY
  136. Remove the 6th gear synchronizer ring (1) from the 5th / 6th gear sleeve carrier.
    137. Fig 86: 5th/6th Gear Selector Sleeve And Spring Catches
    GM2811295Courtesy of GENERAL MOTORS COMPANY
  137. Remove the 5th / 6th gear selector sleeve (2) from the 5th / 6th gear sleeve carrier.
  138. Remove the 3 spring catches (1, 3) from the sleeve carrier.
    139. Fig 87: 5th/6th Gear Selector Sleeve Retainer Ring
    GM2811296Courtesy of GENERAL MOTORS COMPANY
  139. Remove and DISCARD the 5th / 6th gear sleeve carrier retaining ring (1) from the upper main shaft, using the GE-396  pliers.
    140. Fig 88: 5th/6th Gear Selector Sleeve Carrier And Remover
    GM2811299Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the DT-60000-40  remover fits correctly.

  140. Install the DT-60000-40  remover (1) to the 5th / 6th gear sleeve carrier (4).
    • DT-60000-40  remover must be positioned between 5th gear synchronizer ring (3) and 5th gear gearwheel (3).
    • Lift the 5th gear synchronizer ring to gain access.
    141. Fig 89: 5th/6th Gear Selector Sleeve Carrier And Removal Tool
    GM2811300Courtesy of GENERAL MOTORS COMPANY
  141. Support the sleeve carrier, using the DT-60000-40  remover.
  142. Remove the 5th / 6th gear sleeve carrier (2) from the lower main shaft. Press out the lower main shaft.
    143. Fig 90: 5th/6th Gear Sleeve Carrier
    GM2811301Courtesy of GENERAL MOTORS COMPANY
  143. Remove the 5th gear synchronizer ring (2) from the 5th / 6th gear sleeve carrier (1).
    144. Fig 91: Lower Main Shaft And 5th Gearwheel
    GM2811303Courtesy of GENERAL MOTORS COMPANY
  144. Remove the 5th gear gearwheel (1) from the lower main shaft.
    145. Fig 92: 5th Gear Needle Bearing
    GM2811305Courtesy of GENERAL MOTORS COMPANY
  145. Remove the 5th gear needle bearing (1) from the lower main shaft.
    146. Fig 93: Support Ring And Washer
    GM2811306Courtesy of GENERAL MOTORS COMPANY
  146. Remove the support ring (1) and the 2 thrust washers (2) from the lower main shaft.
    147. Fig 94: 2nd Gear Gearwheel
    GM2813966Courtesy of GENERAL MOTORS COMPANY
  147. Remove the 2nd gear gearwheel (1) from the lower main shaft.
    148. Fig 95: 2nd Gear Needle Bearing
    GM2813967Courtesy of GENERAL MOTORS COMPANY
  148. Remove the 2nd gear needle bearing (1) from the lower main shaft.
    149. Fig 96: 2nd Gear Synchronizer Rings
    GM2813968Courtesy of GENERAL MOTORS COMPANY
  149. Remove the three 2nd gear synchronizer rings (1) from the 1st / 2nd gear sleeve carrier (2).
    150. Fig 97: Selector Sleeve
    GM2813970Courtesy of GENERAL MOTORS COMPANY
  150. Remove the selector sleeve (2) from the 1st / 2nd gear sleeve carrier.
  151. Remove the 3 spring catches (1, 3) from the sleeve carrier.
    152. Fig 98: 1st/2nd Gear Sleeve Carrier Retaining Ring
    GM2813971Courtesy of GENERAL MOTORS COMPANY
  152. Remove and DISCARD the 1st / 2nd gear sleeve carrier retaining ring (1) from the lower main shaft, using the GE-396  pliers.
    153. Fig 99: 1st Gear Gearwheel
    GM2813972Courtesy of GENERAL MOTORS COMPANY
  153. Support the 1st gear gearwheel (3), using the DT-60000-50  remover (1).
  154. Remove the 1st / 2nd gear sleeve carrier (2) and the 1st gear gearwheel from the lower main shaft. Press out the lower main shaft.
    155. Fig 100: 1st/2nd Gear Sleeve Carrier
    GM2813973Courtesy of GENERAL MOTORS COMPANY
  155. Remove the 1st / 2nd gear sleeve carrier (1), the 1st gear synchronizer rings (2) and the shim from the 1st gear gearwheel (3). DISCARD the 1st gear gearwheel.
    156. Fig 101: 1st Gear Needle Bearing
    GM2813974Courtesy of GENERAL MOTORS COMPANY
  156. Remove the 1st gear needle bearing (1) from the lower main shaft.
    157. Fig 102: Retaining Ring Clamps
    GM2811247Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    If the retaining ring clamps / stucks, perform the next step at first in order to loosen the retaining ring (1).

  157. Remove and DISCARD the inner bearing retaining ring (1) from the lower main shaft, using the GE-396  pliers.
    158. Fig 103: Supporting Upper Main Shaft, Using Sleeve
    GM2811246Courtesy of GENERAL MOTORS COMPANY
  158. Support the lower main shaft, using the DT-46759  sleeve (2). Press the inner bearing (1) against the gearwheel of the differential gear drive.
    159. Fig 104: Support Sleeve
    GM2813975Courtesy of GENERAL MOTORS COMPANY
  159. Support the inner bearing (1), using the DT-60000-30  sleeve (2).
  160. Remove the inner bearing from the lower main shaft. Press out the lower main shaft.
  161. Clean all components of the lower main shaft.
  162. Dry all components of the lower main shaft.
  163. Check all components of the lower main shaft for damage.
    • Damaged parts must not be installed.
  164. Lubricate all components of the lower main shaft with transmission fluid for corrosion protection.
    165. Fig 105: Special Tool Support Sleeve
    GM2811251Courtesy of GENERAL MOTORS COMPANY
  165. Support the lower main shaft inner bearing (1), using the DT-46759  sleeve (2).
  166. Install the inner bearing to the lower main shaft. Press in the lower main shaft.
    167. Fig 106: Inner Bearing Retaining Ring
    GM2813976Courtesy of GENERAL MOTORS COMPANY
  167. 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.
    168. Fig 107: Retaining Ring Clamps
    GM2811247Courtesy of GENERAL MOTORS COMPANY
  168. Install the NEW inner bearing retaining ring (1) to the lower main shaft, using the GE-396  pliers.
    169. Fig 108: 1st Gear Needle Bearing
    GM2813974Courtesy of GENERAL MOTORS COMPANY
  169. Install the 1st gear needle bearing (1) to the lower main shaft.
    170. Fig 109: 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.

  170. 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.
    171. Fig 110: 1st/2nd Gear Sleeve Carrier And Sleeve
    GM2813978Courtesy of GENERAL MOTORS COMPANY
  171. Position the 1st / 2nd gear sleeve carrier (1) on the DT-46759  sleeve (2).
    172. Fig 111: Ensuring Proper Shim Fit
    GM2813979Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the shim fits correctly.

  172. 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).
    173. Fig 112: 1st Gear Synchronizer Ring
    GM2813980Courtesy of GENERAL MOTORS COMPANY
  173. Position the 1st gear synchronizer ring (1) on the 1st / 2nd gear sleeve carrier.
    174. Fig 113: Positioning Two 1st Gear Synchronizer Rings
    GM2813981Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  174. 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.

    175. Fig 114: 1st Gear Gearwheel
    GM2813982Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the gearwheel fits into the synchronizer ring.

  175. 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.

    176. Fig 115: 1st Gear Needle Bearing
    GM2813984Courtesy of GENERAL MOTORS COMPANY
  176. Position the 1st gear needle bearing (1) into the 1st gear gearwheel.
    177. Fig 116: Positioning Lower Main Shaft Into Sleeve
    GM2813986Courtesy of GENERAL MOTORS COMPANY
  177. Position the lower main shaft (1) into the DT-46759  sleeve (2).
    178. Fig 117: Checking Axial Needle Bearing Fir
    GM2813987Courtesy of GENERAL MOTORS COMPANY
  178. Check that the axial needle bearing (1) fits correctly.
    179. Fig 118: Turning 1st Gear Gearwheel
    GM2813988Courtesy of GENERAL MOTORS COMPANY
  179. Turn the 1st gear gearwheel (1). Turning the gearwheel secures that the synchronizer fits correctly into the gearwheel.
    180. Fig 119: Supporting 1st Gear Gearwheel In Sleeve
    GM2813989Courtesy of GENERAL MOTORS COMPANY
  180. Support the 1st / 2nd gear sleeve carrier (1), using the DT-46759  sleeve (2).
  181. Install the 1st / 2nd gear sleeve carrier and the reverse gear gearwheel to the lower main shaft. Press in the lower main shaft.
  182. Check free rotating of the 1st gear gearwheel.
    183. Fig 120: 1st/2nd Gear Sleeve Carrier Retaining Ring
    GM2813971Courtesy of GENERAL MOTORS COMPANY
  183. Install the NEW 1st / 2nd gear sleeve carrier retaining ring (1) to the lower main shaft, using the GE-396  pliers.
    184. Fig 121: Spring Catches
    GM2813990Courtesy of GENERAL MOTORS COMPANY
  184. Install the 3 spring catches (1, 2) to the 1st / 2nd gear sleeve carrier.
    185. Fig 122: Selector Sleeve
    GM2813993Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  185. 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.
    186. Fig 123: Synchronizer Rings
    GM2813994Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  186. Install the 3 synchronizer rings (1) to the 1st / 2nd gear sleeve carrier (2).
    187. Fig 124: 2nd Gear Needle Bearing
    GM2813967Courtesy of GENERAL MOTORS COMPANY
  187. Install the 2nd gear needle bearing (1) to the lower main shaft.
    188. Fig 125: 2nd Gear Gearwheel
    GM2813966Courtesy of GENERAL MOTORS COMPANY
  188. Install the 2nd gear gearwheel (1) to the lower main shaft.
    189. Fig 126: Turning 2nd Gear Gearwheel
    GM2813995Courtesy of GENERAL MOTORS COMPANY
  189. Turn the 2nd gear gearwheel (1). Turning the gearwheel secures correct fitting of the gearwheel into the synchronizer ring.
    190. Fig 127: Support Ring And Washer
    GM2811306Courtesy of GENERAL MOTORS COMPANY
  190. Install the 2 thrust washers (2) and the support ring (1) to the lower main shaft.
    191. Fig 128: 5th Gear Needle Bearing
    GM2811305Courtesy of GENERAL MOTORS COMPANY
  191. Install the 5th gear needle bearing (1) to the lower main shaft.
    192. Fig 129: Lower Main Shaft And 5th Gearwheel
    GM2811303Courtesy of GENERAL MOTORS COMPANY
  192. Install the 5th gear gearwheel (1) to the lower main shaft.
    193. Fig 130: 5th Gear Synchronizer Ring
    GM2813996Courtesy of GENERAL MOTORS COMPANY
  193. Install the 5th gear synchronizer ring (1) to lower main shaft.
    194. Fig 131: Aligning Synchronizer Ring
    GM2813997Courtesy of GENERAL MOTORS COMPANY
  194. Align the synchronizer ring to the opening in the sleeve carrier (arrows).
    195. NOTE:

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

  195. Install the 5th / 6th gear sleeve carrier (2) to the lower main shaft. Press on the sleeve carrier, using the DT-46759  sleeve (1)
  196. Check free rotating of the 2nd gear gearwheel and 5th gear gearwheel.
    197. Fig 132: 5th/6th Gear Selector Sleeve Retainer Ring
    GM2811296Courtesy of GENERAL MOTORS COMPANY
  197. Install the NEW 5th / 6th gear sleeve carrier retaining ring (1) to the lower main shaft, using the GE-396  pliers.
    198. Fig 133: Spring Catches
    GM2813998Courtesy of GENERAL MOTORS COMPANY
  198. Install the 3 spring catches (1, 2) to the 5th / 6th gear sleeve carrier.
    199. Fig 134: Ensuring Correct Selector Sleeve Position
    GM2813999Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  199. 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.

    200. Fig 135: 6th Gear Synchronizer Ring
    GM2811294Courtesy of GENERAL MOTORS COMPANY
  200. Install the 6th gear synchronizer ring (1) to the 5th / 6th gear sleeve carrier.
    201. Fig 136: 6th Gear Needle Bearing
    GM2811293Courtesy of GENERAL MOTORS COMPANY
  201. Install the 6th gear needle bearing (1) to the lower main shaft.
    202. Fig 137: 6th Gearwheel
    GM2811292Courtesy of GENERAL MOTORS COMPANY
  202. Install the 6th gear gearwheel (1) to the lower main shaft.
    203. Fig 138: Installing Outer Bearing With Special Tool
    GM2814000Courtesy of GENERAL MOTORS COMPANY
  203. 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".
    204. Fig 139: Outer Bearing Retaining Ring
    GM2811286Courtesy of GENERAL MOTORS COMPANY
  204. 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.
  205. Install the NEW outer bearing retaining ring to the lower main shaft, using the GE-396  pliers.
    206. Fig 140: Checking Component Function
    GM2814002Courtesy of GENERAL MOTORS COMPANY
  206. 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.
    207. Fig 141: Special Holder Tool
    GM2814003Courtesy of GENERAL MOTORS COMPANY
  207. Turn the clutch housing along with the DT-6115  holder (1) 180 degree. Clutch side facing upwards.
  208. Secure the DT-6115  holder with the pin.
  209. Remove the clutch actuator cylinder from the clutch housing. Refer to Clutch Actuator Cylinder Replacement .
    210. Fig 142: Turning Clutch Housing
    GM2814006Courtesy of GENERAL MOTORS COMPANY
  210. Turn the clutch housing along with the DT-6115  holder 180 degree. Transmission side facing upwards.
  211. Secure the DT-6115  holder with the pin.
  212. Remove the input shaft seal ring (1), using a pivot and a hammer.
    213. Fig 143: Special Removal Tool
    GM2814007Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    First install the DT-60000-80  remover without bail.

  213. Install the DT-60000-80  remover (1) to the inner bearing outer ring of the lower main shaft. Hand tighten the nut (2).
  214. The remover arms (3) must fit into the pits below the outer ring of the bearing (arrow).
    215. Fig 144: Installing Bail, Remover Bearing And Nut
    GM2814008Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the bail does not push against the outer ring of the bearing (arrow).

  215. Install bail (1), remover bearing (3) and nut (2) to the DT-60000-80  remover.
  216. Turn the nut (2) clockwise. Remove and DISCARD the inner bearing outer ring of the lower main shaft from the clutch housing.
  217. Repeat the steps above for the inner bearing outer ring of the upper main shaft.
    218. Fig 145: Installing Special Removal Tool
    GM2814009Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    First install the DT-60000-70  remover without bail.

  218. Install the DT-60000-70  remover (1) to the inner bearing outer ring of the input shaft. Hand tighten the nut (2).

    The remover arms must fit into the pits below the outer ring of the bearing.

    219. Fig 146: Ball Bearing Remover
    GM2814010Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the bail does not push against the outer ring of the bearing.

  219. Install bail (1), the remover bearing (3) and nut (2) to the DT-60000-70  remover.
  220. Turn the nut clockwise. Remove and DISCARD the inner bearing outer ring of the input shaft from the clutch housing.
    221. Fig 147: Clutch Housing
    GM2814012Courtesy of GENERAL MOTORS COMPANY
  221. Remove the clutch housing (1) from the DT-6115  holder (2). Position the clutch housing on a workbench.
    222. Fig 148: 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.

  222. Determine the correct function side of DT-60000-90  installer (1).
  223. 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.
    224. Fig 149: Special Installation Tool
    GM2814014Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  224. 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.
    225. Fig 150: Installing Outer Rings
    GM2814016Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  225. 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.
    226. Fig 151: Transmission Case Cover
    GM2814130Courtesy of GENERAL MOTORS COMPANY
  226. Install the transmission case cover (1) to the DT-60000-130  holder (3). Install the 2 washers and 2 nuts (2, 4) and tighten.
    227. Fig 152: Adjusting Tool Supports
    GM2814018Courtesy of GENERAL MOTORS COMPANY
  227. Turn the supports (1, 2) counterclockwise and hand tighten.
    228. Fig 153: Marking Shafts
    GM2814019Courtesy of GENERAL MOTORS COMPANY
  228. Mark the positions of the shafts to relief the following steps.
    • I Input shaft
    • II Upper main shaft
    • III Lower main shaft
    229. Fig 154: Outer Bearing Outer Ring Removal Tool
    GM2814020Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    First install the DT-60000-70  remover without bail.

  229. Install the DT-60000-70  remover (1) to the outer bearing outer ring. Hand tighten the nut (2).

    The remover arms (3) must fit into the pits below the outer ring of the bearing (arrow).

    230. Fig 155: Removal Tool Bail
    GM2814021Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the bail does not push against the outer ring of the bearing.

  230. Install the bail (2), remover bearing and nut to the DT-60000-70  remover.
  231. Turn the nut clockwise. Remove and DISCARD the inner bearing outer rings (1) from the clutch housing.
  232. Remove the shim rings and lay aside.
  233. Remove the transmission case cover from the DT-60000-130  holder.
  234. Re-cut 16 transmission case cover bolt threads in the clutch housing.
  235. Re-cut 3 clutch actuator cylinder bolt threads.
    236. NOTE:

    The sealing surfaces must not be treated mechanical (for example with blunt scraper or steel brush). Do not use cleaners that affect plastics, steel or aluminum.

  236. Clean the sealing surface of the clutch housing and the transmission case cover from sealant and debris.
    237. Fig 156: Differential Gear. Openings
    GM2814023Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    During cleaning make sure that no cleaner or debris gets into the differential gear. Openings (1, 2, 3) must be closed with lint free cloth or suitable caps.

  237. Clean all components.
  238. Dry all components.
    239. Fig 157: Clutch Housing
    GM2814012Courtesy of GENERAL MOTORS COMPANY
  239. Install the clutch housing (1) to the DT-6115  holder (2).
  240. Secure the DT-6115  holder with the pin.
    241. Fig 158: Upper And Lower Mainshafts
    GM2814024Courtesy of GENERAL MOTORS COMPANY
  241. Install 2 main shafts (1, 2) to the clutch housing.
  242. Install the 1st / 2nd gear shift fork (3) to the lower main shaft.
  243. Install the reverse gear shift fork (4) to the upper main shaft.
    244. Fig 159: Upper And Lower Mainshaft Forks
    GM2814025Courtesy of GENERAL MOTORS COMPANY
  244. Install the 3rd / 4th gear shift fork (4) to the upper main shaft.
  245. Install the 5th / 6th gear shift fork (3) to the lower main shaft.
  246. Install 2 shift shafts (1, 2) to the clutch housing.
    247. Fig 160: Checking Free Rotating Of All Gearwheels
    GM2814026Courtesy of GENERAL MOTORS COMPANY
  247. Install the input shaft (1) to the clutch housing.

    Lift the lower main shaft a bit.

  248. Check free rotating of all gearwheels.
    249. Fig 161: Outer Bearing Outer Rings And Transmission Shafts
    GM2814027Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The outer rings must be clean to avoid incorrect measurement.

  249. Install 3 NEW outer bearing outer rings (1, 2) to the transmission shafts.
    250. Fig 162: 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.

  250. Install the 2 DT-60000-120-5  spacer (1, 3) to the clutch housing.
  251. Install the 2 DT-60000-120-4  spacer (2, 4) to the clutch housing.
    252. Fig 163: 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.

  252. Install DT-60000-120-1  cylinder (2) to the input shaft.
  253. Install the DT-60000-120-2  cylinder (1) to the upper main shaft.
  254. Install the DT-60000-120-3  cylinder (3) to the lower main shaft.
  255. 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.
    256. Fig 164: 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.

  256. 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).
    257. Fig 165: Turning Transmission Shafts
    GM2814032Courtesy of GENERAL MOTORS COMPANY
  257. 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.
    258. Fig 166: Measuring Clearances
    GM2814033Courtesy of GENERAL MOTORS COMPANY
  258. Use a feeler gauge (2) with 0.05 mm (0.002 in) increments, measure the thickness of the shim rings.
  259. Measure the clearance at the DT-60000-120-1  cylinder (1), DT-60000-120-2  cylinder and DT-60000-120-3  cylinder.
  260. Note the measured values.
    261. Fig 167: 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.

  261. 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).
  262. Note the measured values.
  263. 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
    264. Fig 168: Turning Transmission Shafts
    GM2814032Courtesy of GENERAL MOTORS COMPANY
  264. Remove the DT-60000-140  adapter respectively the DT-60000-150  adapter (1) from the input shaft.
    265. Fig 169: Installing Transmission Case Cover
    GM2814031Courtesy of GENERAL MOTORS COMPANY
  265. 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.
    266. Fig 170: Special Cylinder Tools
    GM2814030Courtesy of GENERAL MOTORS COMPANY
  266. 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.
    267. Fig 171: Special Spacers
    GM2814029Courtesy of GENERAL MOTORS COMPANY
  267. Remove the 2 DT-60000-120-5  spacers (1, 3) from the clutch housing.
  268. Remove the 2 DT-60000-120-4  spacers (2, 4) from the clutch housing.
    269. Fig 172: Outer Bearing Outer Rings And Transmission Shafts
    GM2814027Courtesy of GENERAL MOTORS COMPANY
  269. Remove the 3 NEW outer bearing outer rings (1, 2) from the transmission shafts.
    270. Fig 173: Transmission Case Cover
    GM2814130Courtesy of GENERAL MOTORS COMPANY
  270. Install transmission case cover (1) to the DT-60000-130  holder (3). Install 2 washers and 2 nuts (2, 4) and tighten.
    271. Fig 174: Adjusting Tool Supports
    GM2814018Courtesy of GENERAL MOTORS COMPANY
  271. Turn the supports (1, 2) counterclockwise and hand tighten.
    272. Fig 175: Shim Rings
    GM2814036Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure to use the measured and calculated shim rings.

  272. Install 3 NEW shim rings (1) to the transmission case cover.
    273. Fig 176: 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.

  273. 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.

    274. Fig 177: Installing Bearings With Special Tool
    GM2814037Courtesy of GENERAL MOTORS COMPANY
  274. 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.
  275. Remove the transmission case cover from the DT-60000-130  holder.
    276. Fig 178: Transmission Magnet
    GM2814038Courtesy of GENERAL MOTORS COMPANY
  276. Install the transmission magnet (1) to the clutch housing.
    277. Fig 179: Neutral Gear
    GM2811168Courtesy of GENERAL MOTORS COMPANY
  277. Install the shift control housing (1) to the clutch housing.
  278. Install the 2 shift control housing bolts (2, 3) and tighten to 20 N.m (15 lb ft).
    279. Fig 180: Backup Lamp Switch
    GM2811167Courtesy of GENERAL MOTORS COMPANY
  279. Install the backup lamp switch (1) to the clutch housing and tighten to 20 N.m (15 lb ft).
    280. Fig 181: Applying Sealant To Case Cover
    GM2814040Courtesy of GENERAL MOTORS COMPANY
  280. Clean the sealing surface at the transmission case cover. The sealing surface must be free from oil and grease.
  281. 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.
    282. Fig 182: Case Cover Bolt Tightening Sequence
    GM2814041Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Bolt 16 must be positioned in original position.

  282. Install the transmission case cover. Install the 16 transmission case cover bolts and tighten a first pass to 5 N.m (44 lb in).
  283. Tighten the transmission case cover bolts a final pass to an additional 21 N.m (16 lb ft).
  284. Check bolt torque. Clockwise check every bolt 21 N.m (16 lb ft).
  285. Turn the clutch housing and the DT-6115  holder (1) 180 degree. Clutch side facing upwards.
  286. Secure the DT-6115  holder with the pin.
    287. Fig 183: 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.

  287. 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.
  288. Install the clutch actuator cylinder to the clutch housing. Refer to Clutch Actuator Cylinder Replacement .
    289. Fig 184: Transmission And Holder Tool
    GM2811164Courtesy of GENERAL MOTORS COMPANY
  289. Turn the clutch housing (1) and the DT-6115  holder (2) 180 degree. Transmission side facing upwards.
  290. Secure the DT-6115  holder with the pin.
    291. NOTE:

    2nd technician required.

  291. Remove the 2 bolts. Remove the transmission from the DT-6115  holder.
  292. 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.

    293. 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.

  293. Install the transmission. Refer to Transmission Replacement .
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