Transmission Assemble

Special Tools

• 3-9506289  Universal Adapter
• R-0007758  Holding Fixture
• S-9407197  Differential Rotating Tool
• S-9407198  Differential Bearing Race Wrench

For equivalent regional tools, refer to Special Tools .

Fig 1: Cutch & Differential Housing Assembly Holding Fixture
Courtesy of GENERAL MOTORS COMPANY
1. Install the clutch and differential housing assembly (1) onto the R-0007758  holding fixture.
Fig 2: Front Differential Carrier
Courtesy of GENERAL MOTORS COMPANY
2. Install the front differential carrier (1).
Fig 3: Front Differential Carrier Cover, Bolts & Gasket
Courtesy of GENERAL MOTORS COMPANY
3. Install the gasket (3) and differential carrier cover (2).
4. Install the front differential carrier cover bolts (1). Tighten to 7 N.m (61.96 lb in).
Fig 4: Front Differential Bearing Adjuster & O-Ring Seal
Courtesy of GENERAL MOTORS COMPANY
5. Lubricate the O-ring seal (2) with multipurpose grease and install onto the differential bearing adjuster (1).
6. Lubricate the threads on the differential bearing adjuster with multipurpose grease.
7. Using S-9407198  differential bearing race wrench install the front differential bearing adjuster (1).
Fig 5: Identifying Differential Bearing Adjuster & Case Alignment Marks
Courtesy of GENERAL MOTORS COMPANY
NOTE:

If all the components are re-used align adjuster to marks. If any component was replaced go to the next step.

8. Align marks on the differential bearing adjuster and case (1).
Fig 6: Differential Rotating Tool
Courtesy of GENERAL MOTORS COMPANY
NOTE:

If no components were replaced, the bearing adjuster can be aligned to the marks. If any component was replaced, the following procedure must be performed.

9. Using the S-9407197  differential rotating tool and a torque wrench, rotate the differential (1) 1 revolution per second.
10. The breakaway bearing torque should be:
    • Re-use bearing - 60-100 Ncm
    • New Bearing - 150-210 Ncm
11. Using the S-9407198  bearing race wrench and the R-0007761  handle, adjust the breakaway torque by tightening or loosing the differential bearing adjuster.
Fig 7: Differential Bearing Adjuster Lock & Bolt
Courtesy of GENERAL MOTORS COMPANY
12. Install the differential bearing adjuster lock (2).
13. Apply thread locking compound and install the differential bearing adjuster lock bolt (1). Tighten to 9 N.m (79.66 lb in).
Fig 8: Back Up Lamp Switch
Courtesy of GENERAL MOTORS COMPANY
14. Install the back up lamp switch (1). Tighten to 20 N.m (14.75 lb ft).
Fig 9: Transmission Case Components
Courtesy of GENERAL MOTORS COMPANY
15. Install the reverse idler gear washer (5).
16. Verify fork alignment before installation.
17. Install the case .
18. Install the gasket (1) and transmission case (2).
19. Install the transmission case bolts (3). Tighten to 15 N.m (11 lb ft).
Fig 10: Transmission Cover, Gasket & Bolts
Courtesy of GENERAL MOTORS COMPANY
20. Install the gasket (4) and transmission cover (3).
21. Install the long transmission cover bolts (2). Tighten to 24 N.m (18 lb ft).
22. Install the short transmission cover bolts (1). Tighten to 8 N.m (71 lb in).
Fig 11: Clutch Release Bearing
Courtesy of GENERAL MOTORS COMPANY
23. Install the clutch release bearing (1).
Fig 12: Control Lever Housing, Gasket & Bolts
Courtesy of GENERAL MOTORS COMPANY
24. Install the gasket (3) and control lever housing (2).
25. Install the transmission control lever housing bolts (1). Tighten to 12 N.m (106 lb in).
Fig 13: Clutch Fork Shaft & Retaining Bolt
Courtesy of GENERAL MOTORS COMPANY
26. Install the clutch fork shaft (1).
27. Install the clutch fork shaft retaining bolt (2). Tighten to 35 N.m (26 lb ft).
Fig 14: Transmission Holding Fixture & Universal Adapter
Courtesy of GENERAL MOTORS COMPANY
28. Remove the R-0007758  holding fixture (2) and the 3-9506289  Universal Adapter (1).