Transmission Case Disassemble (Gen 2)

Special Tools

• 3-9506289  Universal Adapter
• J-810700  Mainshaft Bearing Remover
• J-810704  Center Bar Puller
• M-680770  Universal Sliding Mallet
• R-0007758  Holding Fixture
• R-0007770  Holding Fixture Adapter Plates
• T-0307000  Extractor and Driver Fixture
• T-9807671  Slide Hammer

For equivalent regional tools, refer to Special Tools .

Fig 1: Transmission Case Assembly Holding Fixture Adapter Plates
Courtesy of GENERAL MOTORS COMPANY
1. Install both plates of the R-0007770  holding fixture adapter plates to the transmission case assembly (1).
Fig 2: Transmission Case Assembly Holding Fixture & Adapter Plates
Courtesy of GENERAL MOTORS COMPANY
2. Install the transmission case, with the R-0007770  holding fixture adapter plates (1) to the R-0007758  holding fixture (2) and 3-9506289  universal adapter.
Fig 3: 5th Shift Fork Bracket Assembly & Retaining Bolts
Courtesy of GENERAL MOTORS COMPANY
3. Remove the 5th shift fork bracket retaining bolts (1).
4. Remove the 5th shift fork bracket assembly (2).
Fig 4: 5th Gear Synchronized Hub Retaining Ring
Courtesy of GENERAL MOTORS COMPANY
5. Remove the 5th gear synchronizing hub retaining ring (1).
Fig 5: 5th Gear Synchronizer Assembly Puller
Courtesy of GENERAL MOTORS COMPANY
6. Using the J-810704  puller, remove the 5th gear synchronizer assembly (1).
Fig 6: 5th Gear Driven & Bearing Assemblies With Blocking Ring
Courtesy of GENERAL MOTORS COMPANY
7. Remove the 5th gear blocking ring (1).
8. Remove the 5th gear assembly, driven (2).
9. Remove the 5th gear bearing assembly (3).
Fig 7: 5th Gear Retaining Ring
Courtesy of GENERAL MOTORS COMPANY
10. Remove the 5th gear retaining ring (1).
Fig 8: 5th Driving Gear Puller
Courtesy of GENERAL MOTORS COMPANY
11. Using the J-810704  puller, remove the 5th gear, driving (1).
Fig 9: Parking Pawl & Retaining Bolts
Courtesy of GENERAL MOTORS COMPANY
NOTE:

The parking pawl bolts are micro-encapsulated and may require that the transmission case be heated to 80°C (176°F) with a heat gun.

12. Remove the parking pawl retaining bolts (1).
13. Remove the parking pawl (2).
Fig 10: Shift Shaft Detent Sleeves & Removal Tools
Courtesy of GENERAL MOTORS COMPANY
14. Using the M-680770  sliding mallet adapter (2) and the T-9807671  slide hammer (1), remove the 4 shift shaft detent sleeves (3-6) from the transmission case.
Fig 11: Shift Shaft Interlock Pin Connector & Bolts
Courtesy of GENERAL MOTORS COMPANY
NOTE:
• The bolts are micro-encapsulated and may require that the transmission case be heated to 80°C (176°F) with a heat gun.
• Engage the shift shafts into 2nd gear, 5th gear, and 3rd gear as indicated with arrows to remove the interlock pin connector.
15. Remove the shift shaft interlock pin connector bolts (2).
16. Remove the shift shaft interlock pin connector (1).
Fig 12: Reverse Shift Fork, Shaft & Components
Courtesy of GENERAL MOTORS COMPANY
17. Remove the reverse shift fork pin (4).
18. Remove the reverse shift shaft (3).
19. Remove the reverse shift fork (5).
20. Remove the reverse fork block pin (2).
21. Remove the reverse fork block (1).
Fig 13: Block Of Wood & Gearshift Rod Guides
Courtesy of GENERAL MOTORS COMPANY
22. Use a block of wood (1) to relieve the pressure on the gearshift rod guides.
Fig 14: 3rd & 4th Shift Shaft, Fork & Pin
Courtesy of GENERAL MOTORS COMPANY
23. Remove the 3rd and 4th shift fork pin (3).
24. Remove the 3rd and 4th shift shaft (1).
25. Remove the 3rd and 4th shift fork (2).
Fig 15: 5th Shift Blocking Guide
Courtesy of GENERAL MOTORS COMPANY
26. Remove the 5th shift blocking guide (1) from the transmission case.
Fig 16: Block Of Wood & Gearshift Rod
Courtesy of GENERAL MOTORS COMPANY
27. Remove the gearshift rod (1) from the transmission case.
28. Insert a block of wood (2) to relieve pressure on the gearshift rod guides.
Fig 17: 1st and 2nd Shift Shaft Components
Courtesy of GENERAL MOTORS COMPANY
29. Remove the 1st and 2nd shift fork pin (5).
30. Remove the 1st and 2nd shift shaft (1).
31. Remove the 1st and 2nd shift fork (4).
32. Remove the 1st and 2nd shaft block pin (3).
33. Remove the 1st and 2nd shaft block (2).
Fig 18: Input Shaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS COMPANY
34. Remove the input shaft bearing retaining ring (1) from the bore, and leave it on the shaft.
Fig 19: Reverse Spur Gear Bearing, Washer & Shaft Snap Ring
Courtesy of GENERAL MOTORS COMPANY
35. Remove the reverse gear shaft snap ring (3), reverse spur gear washer (2), and reverse spur gear bearing (1).
Fig 20: Reverse Idler Gear, Input Shaft & Mainshaft
Courtesy of GENERAL MOTORS COMPANY
36. Remove the transmission case from R-0007770  adapter plates and install onto the T-0307000  fixture.
NOTE:

Be prepared to support the reverse idler gear, input shaft and mainshaft as they are pressed from the case.

37. Support the mainshaft (3), input shaft (2) and reverse idler gear (1) while pressing the shafts from the case.
Fig 21: 5th Gear Bearing Race, Main Shaft & Helical Gear Components
Courtesy of GENERAL MOTORS COMPANY
38. Remove the following components from the T-0307000  fixture.
    • Main shaft (2)
    • Reverse spur gear (3)
    • Reverse synchro assembly (4)
    • Reverse helical gear (5)
    • Input Shaft (6)
39. Remove the 5th gear bearing race (1) from the transmission case.
Fig 22: Mainshaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS COMPANY
40. Remove the mainshaft bearing retaining ring (1).
Fig 23: Mainshaft Bearing & Remover
Courtesy of GENERAL MOTORS COMPANY
41. Using J-810700  mainshaft bearing remover, remove the mainshaft bearing (1) from the case.
Fig 24: Reverse Idler Gear Shaft, Retaining Ball & Reverse Helical Gear Washer
Courtesy of GENERAL MOTORS COMPANY
42. Remove the reverse idler gear shaft (1) from the case.
43. Remove the reverse idler gear shaft retaining ball (2).
44. Remove the reverse helical gear washer (3).