Transmission Case Assemble (Gen 2)

Special Tools

• 3-9506289  Universal Adapter
• J-840733  Driver
• R-0007758  Holding Fixture
• R-0007761  Universal Handle
• R-0007770  Holding Fixture Adapter Plates
• T-9804669  Seal Installer
• T-0307000  Extractor and Driver Fixture

For equivalent regional tools, refer to Special Tools .

Fig 1: Reverse Idler Gear Shaft, Retaining Ball & Reverse Helical Gear Washer
Courtesy of GENERAL MOTORS COMPANY
1. Install the reverse helical gear washer (3) onto the reverse idler gear shaft.
2. Install the reverse idler gear shaft retaining ball (2).
3. Install the reverse idler gear shaft (1).
Fig 2: Mainshaft Bearing Installation Tools
Courtesy of GENERAL MOTORS COMPANY
4. Using T-9804669  seal installer (2) and R-0007761  handle (1), install the mainshaft bearing (3) into the case.
Fig 3: Mainshaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS COMPANY
5. Install the mainshaft bearing retaining ring (1).
Fig 4: 5th Gear Bearing Race, Main Shaft & Helical Gear Components
Courtesy of GENERAL MOTORS COMPANY
6. Install the following components onto the T-0307000  driver fixture with top plate removed.
   • Main shaft (2)
   • Reverse helical gear (5)
   • Reverse synchro assembly (4)
   • Reverse spur gear (3)
   • Input Shaft (6)
Fig 5: Reverse Idler Gear & Guide Shafts
Courtesy of GENERAL MOTORS COMPANY
NOTE:

While pressing, pay attention to the input shaft bearing retaining ring, because it can be pressed into the first gear.

7. Guide the shafts (1-2) into the bores, and support the reverse idler gear (3) while pressing into the case.
Fig 6: 5th Gear Bearing Race & Driver Fixture
Courtesy of GENERAL MOTORS COMPANY
8. Using the T-0307000  driver fixture, press the 5th gear bearing race (1) onto the mainshaft.
Fig 7: Reverse Spur Gear Bearing, Washer & Shaft Snap Ring
Courtesy of GENERAL MOTORS COMPANY
9. Install the reverse spur gear bearing (1), reverse spur gear washer (2), and reverse gear shaft snap ring (3).
Fig 8: Case & Shaft Assembly Installation Tools
Courtesy of GENERAL MOTORS COMPANY
10. Install the case and shafts assembly onto the R-0007770  adapter plates (1) and R-0007758  holding fixture (2).
Fig 9: Input Shaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS COMPANY
11. Install the input shaft bearing retaining ring (1).
Fig 10: 1st and 2nd Shift Shaft Components
Courtesy of GENERAL MOTORS COMPANY
12. Install the 1st and 2nd shaft block (2).
13. Install the 1st and 2nd shaft block pin (3) to the dimension "a" depth of 2 mm (0.80 in).
14. Install the 1st and 2nd shift fork (4).
15. Install the 1st and 2nd shift shaft (1).
16. Install the 1st and 2nd shift fork pin (5) to the dimension "a" depth of 2 mm (0.80 in).
Fig 11: Gearshift Rod
Courtesy of GENERAL MOTORS COMPANY
17. Install the gearshift rod (1) into the transmission case.
Fig 12: 5th Shift Blocking Guide
Courtesy of GENERAL MOTORS COMPANY
18. Install the 5th shift blocking guide (1) into the transmission case.
Fig 13: 3rd/4th Shift Fork, Pin & Shaft
Courtesy of GENERAL MOTORS COMPANY
19. Install the 3rd and 4th shift fork (2).
20. Install the 3rd and 4th shift shaft (1).
21. Install the 3rd and 4th shift fork pin (3) to the dimension "a" depth of 2 mm (0.80 in).
Fig 14: Reverse Shift Fork, Shaft & Components
Courtesy of GENERAL MOTORS COMPANY
22. Install the reverse fork block (1).
23. Install the reverse fork block pin (2) to the dimension "a" depth of 2 mm (0.80 in).
24. Install the reverse shift fork (5).
25. Install the reverse shift shaft (3).
26. Install the reverse shift fork pin (4) to the dimension "a" depth of 2 mm (0.80 in).
Fig 15: Shift Shaft Detent Sleeves (1-4)
Courtesy of GENERAL MOTORS COMPANY
27. Using a plastic hammer or equivalent install the 4 shift shaft detent sleeves (1-4) into the transmission case until they stop.
Fig 16: Shift Shaft Interlock Pin Connector & Bolts
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Engage the shift shafts into 2nd gear, 5th gear, and 3rd gear as indicated with arrows to install the interlock pin connector.

28. Install the shift shaft interlock pin connector (1).
29. Using thread locking compound install the shift shaft interlock pin connector bolts (2) and tighten to 7 N.m (62 lb in).
Fig 17: Parking Pawl & Retaining Bolts
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Move shift forks into neutral position.

30. Install the parking pawl (2).
CAUTION:

Refer to Fastener Caution .

31. Using thread locking compound install the parking pawl retaining bolts (1) and tighten to 7 N.m (62 lb in).
Fig 18: 5th Gear (Driven)
Courtesy of GENERAL MOTORS COMPANY
32. Remove case and shafts assembly from R-0007770  adapter plates and install onto T-0307000  driver fixture.
33. Using J-840733  driver, press the 5th gear, driving (1) onto the input shaft.
Fig 19: 5th Gear Retaining Ring
Courtesy of GENERAL MOTORS COMPANY
34. Install a NEW 5th gear retaining ring (1).
Fig 20: 5th Gear Driven & Bearing Assemblies With Blocking Ring
Courtesy of GENERAL MOTORS COMPANY
35. Install the 5th gear bearing assembly (3).
36. Install the 5th gear assembly, driven (2).
37. Install the 5th gear blocking ring (1).
Fig 21: Synchronizer Assembly
Courtesy of GENERAL MOTORS COMPANY
38. Ensure that the synchronizer assembly (1) is functioning properly, refer to Synchronizers Cleaning and Inspection , and Synchronizers Assemble .
39. Using the J-840733  driver and a press, install the 5th gear synchronizer assembly (1).
Fig 22: 5th Gear Synchronized Hub Retaining Ring
Courtesy of GENERAL MOTORS COMPANY
40. Install the 5th gear sychronizing hub retaining ring (1).
Fig 23: Case & Shaft Assembly Removal Tools
Courtesy of GENERAL MOTORS COMPANY
41. Remove the case and shafts assembly from the T-0307000  driver fixture.
42. Install R-0007770  adapter plates (1) onto case (2) and then attach to R-0007758  holding fixture (3).
Fig 24: 5th Shift Fork Components
Courtesy of GENERAL MOTORS COMPANY
43. Install the 5th shift fork shoes (3).
44. Install the 5th shift fork bracket assembly (2).
45. Using thread locking compound install the 5th shift fork bracket bolts (1) and tighten to 22 N.m (16 lb ft).
Fig 25: Transmission Case Assembly Holding Fixture & Adapter Plates
Courtesy of GENERAL MOTORS COMPANY
46. Remove the transmission case, from the R-0007770  adapter plates (1) the R-0007758  holding fixture and 3-9506289  adapter.