LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2015 >> Cruze LT, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Manual Transmission - M32) >> Repair Instructions - On Vehicle >> Input and Main Shaft Bearing Replacement >> Shimming Procedure

Shimming Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Release the pin (2) to unlock the DT-6115  holder (1).
    Fig 1: Identifying DT-6115 Holder
    GM4081150Courtesy of GENERAL MOTORS COMPANY
  2. Turn the clutch housing along with the DT-6115  holder 180 degrees. Clutch side facing upwards.
  3. Lock the DT-6115  holder with the pin.
  4. Remove the clutch actuator cylinder pipe (2) from the clutch actuator cylinder pipe sleeve (1). Push the lashes in direction of the arrows to release the pipe.
    Fig 2: Clutch Actuator Cylinder Pipe And Clutch Actuator Cylinder Pipe Sleeve
    GM4067582Courtesy of GENERAL MOTORS COMPANY
  5. Clutch Actuator Cylinder Bolt (2)»Remove and DISCARD [3x]
    Fig 3: Identifying Clutch Actuator Cylinder Bolts
    GM4081151Courtesy of GENERAL MOTORS COMPANY
  6. Clutch Actuator Cylinder (1)»Remove
  7. Release the pin (2) to unlock the DT-6115  holder (1).
    Fig 4: Identifying DT-6115 Holder
    GM4081150Courtesy of GENERAL MOTORS COMPANY
  8. Turn the clutch housing along with the DT-6115  holder 180 degrees. Transmission side facing upwards.
  9. Lock the DT-6115  holder with the pin.
  10. Remove and DISCARD the input shaft seal ring (1), using a arbor and a hammer.
    Fig 5: Identifying Input Shaft Seal Ring
    GM4081152Courtesy of GENERAL MOTORS COMPANY
  11. Install the DT-60000-180  lifter (1) to the inner bearing outer ring of the lower main shaft (2). The DT-60000-180  lifter must fit correctly into the pits under the bearing ring (arrow).
    Fig 6: Identifying DT-60000-180 Lifter
    GM4090950Courtesy of GENERAL MOTORS COMPANY
  12. Tighten the DT-60000-180  lifter, using a 24 mm open-end wrench, in order to lift the inner bearing outer ring of the lower main shaft.
  13. Remove the DT-60000-180  lifter.
  14. Install the DT-60000-80  remover (1) to the inner bearing outer ring of the lower main shaft. Hand tighten the nut (2).
    Fig 7: Special Removal Tool
    GM2814007Courtesy of GENERAL MOTORS COMPANY
    NOTE: First install the DT-60000-80  remover without bail.
  15. The remover arms (3) must fit into the pits below the outer ring of the bearing (arrow).
    Fig 8: Installing Bail, Remover Bearing And Nut
    GM2814008Courtesy of GENERAL MOTORS COMPANY
  16. Install bail (1), remover bearing (3) and nut (2) to the DT-60000-80  remover.
    NOTE: Make sure that the bail does not push against the outer ring of the bearing (arrow).
  17. Turn the nut (2) clockwise. Remove and DISCARD the inner bearing outer ring of the lower main shaft from the clutch housing.
  18. Repeat the steps above for the inner bearing outer ring of the upper main shaft.
  19. Install the DT-60000-70  remover (1) to the inner bearing outer ring of the input shaft. Hand tighten the nut (2).
    Fig 9: Installing Special Removal Tool
    GM2814009Courtesy of GENERAL MOTORS COMPANY
    NOTE: First install the DT-60000-70  remover without bail.

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

  20. Install bail (1), the remover bearing (3) and nut (2) to the DT-60000-70  remover.
    Fig 10: Ball Bearing Remover
    GM2814010Courtesy of GENERAL MOTORS COMPANY
    NOTE: Make sure that the bail does not push against the outer ring of the bearing.
  21. Turn the nut clockwise. Remove and DISCARD the inner bearing outer ring of the input shaft from the clutch housing.
  22. Remove the clutch housing (1) from the DT-6115  holder (2). Position the clutch housing on a workbench.
    Fig 11: Clutch Housing
    GM2814012Courtesy of GENERAL MOTORS COMPANY
  23. Determine the correct function side of DT-60000-90  installer (1).
    Fig 12: 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.
  24. 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.
  25. 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.
    Fig 13: Special Installation Tool
    GM2814014Courtesy of GENERAL MOTORS COMPANY
    NOTE: Failure to install the outer ring completely will cause incorrect measurement of the shim ring.
  26. 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.
    Fig 14: Installing Outer Rings
    GM2814016Courtesy of GENERAL MOTORS COMPANY
    NOTE: Failure to install the outer rings completely will cause incorrect measurement of the shim rings.
  27. Disassemble the DT-60000-130  support
    Fig 15: Identifying DT-60000-130-2 Spacer And DT-60000-130-3 Support
    GM4081155Courtesy of GENERAL MOTORS COMPANY
    1. Remove the 2 DT-60000-130-2  spacer (2).
    2. Remove the 3 DT-60000-130-3  support (1).
  28. Install the DT-60000-135  adapter
    Fig 16: Locating DT-60000-135-3 Grub Screw, DT-60000-135-1 Adapter Plate, DT-60000-130-3 Support And DT-60000-135-2 Spacer
    GM4081156Courtesy of GENERAL MOTORS COMPANY
    1. Install the DT-60000-135-3  grub screw (4) to the DT-60000-130  plate.
    2. Position the DT-60000-135-1  adapter plate (1) on the DT-60000-130  plate.
    3. Install the 3 DT-60000-130-3  support (3) to the DT-60000-130  plate.
    4. Install the 2 DT-60000-135-2  spacer (2) to the DT-60000-130  plate.
  29. Install the transmission case (1) to the DT-60000-130  support (3). Install the 2 washers and 2 nuts (2, 4) and tighten.
    Fig 17: Identifying Transmission Case, DT-60000-130 Support, Washers And Nuts
    GM4081157Courtesy of GENERAL MOTORS COMPANY
  30. Turn the supports (1, 2) counterclockwise and hand tighten.
    Fig 18: Identifying Supports
    GM4081162Courtesy of GENERAL MOTORS COMPANY
  31. Mark the positions of the shafts to relief the following steps.
    Fig 19: Marking Positions Of Shafts
    GM4081170Courtesy of GENERAL MOTORS COMPANY
    NOTE: Use a permanent marker.
    1. I = Input shaft
    2. II = Upper main shaft
    3. III = Lower main shaft
  32. Install the DT-60000-85  remover to the bearing cup.
    Fig 20: Identifying Special Nut
    GM4081172Courtesy of GENERAL MOTORS COMPANY
    1. Position the DT-60000-85  remover to the bearing cup.
    2. Turn the nut (1) in the respective direction to reach the correct depth of the cone (arrow).
    3. Hold the spindle with a 8 mm open-end wrench (3) and turn the special nut (2) clockwise in order to spread the cone beneath the bearing cup (arrow).
  33. Remove the bearing cup (4).
    Fig 21: Identifying Bearing Cup And Shim Ring
    GM4081173Courtesy of GENERAL MOTORS COMPANY
    NOTE: Make sure that the bail does not shore up at the bearing cup (arrow).
    1. Hold the spindle with a 8 mm open-end wrench (1) and turn the nut clockwise with a 19 mm open-end wrench (2) in order to pull the bearing cup out.
    2. After removal release the bearing cup and the shim ring (3) from the DT-60000-85  remover.
  34. Repeat the 2 previous steps in order to remove all bearing cups and shim rings (2) from the transmission case.
  35. DISCARD all bearing cups and all shim rings.
  36. Remove the transmission case (1) from the DT-60000-130  support (3).
    Fig 22: Identifying Transmission Case, DT-60000-130 Support, Washers And Nuts
    GM4081157Courtesy of GENERAL MOTORS COMPANY
  37. Release the pin (2) to unlock the DT-6115  holder (1).
    Fig 23: Identifying DT-6115 Holder
    GM4081150Courtesy of GENERAL MOTORS COMPANY
  38. Turn the clutch housing along with the DT-6115  holder 180 degrees. Clutch side facing upwards.
  39. Lock the DT-6115  holder with the pin.
  40. Re-cut 3 clutch actuator cylinder bolt threads (1) in the clutch housing.
    Fig 24: Identifying Clutch Actuator Cylinder Bolt Threads
    GM4088048Courtesy of GENERAL MOTORS COMPANY
  41. Release the pin (2) to unlock the DT-6115  holder (1).
    Fig 25: Identifying DT-6115 Holder
    GM4081150Courtesy of GENERAL MOTORS COMPANY
  42. Turn the clutch housing along with the DT-6115  holder 180 degrees. Transmission side facing upwards.
  43. Lock the DT-6115  holder with the pin.
  44. Re-cut 16 transmission case bolt threads (1) in the clutch housing.
    Fig 26: Identifying Transmission Case Bolt Threads
    GM4088049Courtesy of GENERAL MOTORS COMPANY
  45. Clean the sealing surface of the clutch housing and the transmission case from sealant and debris.
    Fig 27: Identifying Openings
    GM4081175Courtesy of GENERAL MOTORS COMPANY
    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.
  46. Clean all components.
    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.
  47. Dry all components.
  48. Install the upper main shaft (1) and the lower main shaft (2).
    Fig 28: Identifying Upper Main Shaft And Lower Main Shaft
    GM4081108Courtesy of GENERAL MOTORS COMPANY
  49. Input Shaft (1)»Install
    Fig 29: Locating Input Shaft
    GM4081106Courtesy of GENERAL MOTORS COMPANY
  50. Install the shift forks (3, 4).
    Fig 30: Identifying Shift Shafts And Shift Forks
    GM4081104Courtesy of GENERAL MOTORS COMPANY
    NOTE: Shift the synchronizer sleeves to gain space for installation.
  51. Install the shift shafts (1, 2).
  52. Check free rotating of all gears.
  53. Install the 3 NEW bearing cups (1, 2) to their respective shaft.
    Fig 31: Identifying Bearing Cups
    GM4081179Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • The bearing cups must be clean to avoid failure in the following measurement.
    • The bearing cups were previously marked.
      • I = Input shaft
      • II = Upper main shaft
      • III = Lower main shaft
  54. Install the 2 DT-60000-125-4  spacer (1, 3) to the clutch housing.
    Fig 32: Identifying Spacers
    GM4081180Courtesy of GENERAL MOTORS COMPANY
    NOTE: The 2 DT-60000-125-4  spacer must be installed on the position of the clutch housing locating pins.
  55. Install the 2 DT-60000-125-3  spacer (2, 4) to the clutch housing.
  56. Install the 3 DT-60000-125-2  adapter (5) to the bearing cups.
    Fig 33: Identifying Cylinders And Adapters
    GM4081182Courtesy of GENERAL MOTORS COMPANY
    NOTE: DT-60000-120-1  cylinder, DT-60000-120-2  cylinder, DT-60000-120-3  cylinder, DT-60000-125-1  adapter and DT-60000-125-2  adapter must be clean at their contact areas to avoid failure in the measurement.
  57. Install the DT-60000-120-1  cylinder (1) to the input shaft.
  58. Install the DT-60000-120-2  cylinder (2) to the upper main shaft.
  59. Install the DT-60000-120-3  cylinder (3) to the lower main shaft.
  60. Install the 3 DT-60000-125-1  adapter (4) to the measuring cylinders.
  61. 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.
  62. Install the transmission case (1) to DT-60000-125-3  spacer and the DT-60000-125-4  spacer.
    Fig 34: Identifying Transmission Case
    GM4081185Courtesy of GENERAL MOTORS COMPANY
    NOTE: DT-60000-125-1  adapter and transmission case must be clean at their contact areas. The 3 DT-60000-125-1  adapter must fit into the transmission case bore for the shaft bearings.
  63. Install 4 washers (3) and 4 nuts (2) and cross tighten to 10 N.m (89 lb in).
    CAUTION: Fastener Caution
  64. Turn the transmission shafts.
    Fig 35: Identifying DT-60000-150 Turning Tool
    GM4081186Courtesy of GENERAL MOTORS COMPANY
    1. Install the DT-60000-140  turning tool respectively the DT-60000-150  turning tool (1)
      NOTE: The correct special tool depends on the input shaft diameter at position of the clutch driven plate.
    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.
  65. Use a feeler gauge (2) with 0.05 mm (0.0002 in) increments to measure the gap at the measuring cylinders.
    Fig 36: Identifying Feeler Gauge
    GM4081188Courtesy of GENERAL MOTORS COMPANY
  66. Measure the gap at the DT-60000-120-1  cylinder (1), DT-60000-120-2  cylinder and DT-60000-120-3  cylinder.
  67. Note the measured values.
  68. 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).
    Fig 37: Locating DT-60000-120-1 Cylinder, DT-60000-120-2 Cylinder And DT-60000-123-3 Cylinder
    GM4081189Courtesy 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.
  69. Note the measured values.
  70. Calculate the thickness of the NEW shim rings:
    • Input shaft: measured value + 0.15 mm (0.006 in) = shim ring thickness
    • Upper main shaft: measured value + 0.3 mm (0.012 in) = shim ring thickness
    • Lower main shaft: measured value + 0.3 mm (0.012 in) = shim ring thickness
  71. Remove the DT-60000-140  turning tool respectively the DT-60000-150  turning tool (1) from the input shaft.
    Fig 38: Identifying DT-60000-150 Turning Tool
    GM4081186Courtesy of GENERAL MOTORS COMPANY
  72. Remove 4 nuts and washers (2, 3).
    Fig 39: Identifying Transmission Case
    GM4081185Courtesy of GENERAL MOTORS COMPANY
  73. Remove the transmission case (1) from the DT-60000-125-3  spacer and the DT-60000-125-4  spacer.
  74. Remove the 3 DT-60000-125-1  adapter (4) from the measuring cylinders.
    Fig 40: Identifying Cylinders And Adapters
    GM4081182Courtesy of GENERAL MOTORS COMPANY
  75. Remove the DT-60000-120-1  cylinder (1), DT-60000-120-2  cylinder (2) and DT-60000-120-3  cylinder (3) from the transmission shafts.
  76. Remove the 3 DT-60000-125-2  adapter (5) from the bearing cups.
  77. Remove the 2 DT-60000-125-3  spacer (2, 4) from the clutch housing.
    Fig 41: Identifying Spacers
    GM4081180Courtesy of GENERAL MOTORS COMPANY
  78. Remove the 2 DT-60000-125-4  spacer (1, 3) from the clutch housing.
  79. Remove the NEW bearing cups (1, 2) from the shafts.
    Fig 42: Identifying Bearing Cups
    GM4081179Courtesy of GENERAL MOTORS COMPANY
  80. Install the transmission case (1) to the DT-60000-130  support (3). Install the 2 washers and 2 nuts (2, 4) and tighten.
    Fig 43: Identifying Transmission Case, DT-60000-130 Support, Washers And Nuts
    GM4081157Courtesy of GENERAL MOTORS COMPANY
  81. Turn the supports (1, 2) counterclockwise and hand tighten.
    Fig 44: Identifying Supports
    GM4081162Courtesy of GENERAL MOTORS COMPANY
  82. Install 3 NEW shim rings (1) to the transmission case.
    Fig 45: Identifying Shim Rings
    GM4081190Courtesy of GENERAL MOTORS COMPANY
    NOTE: Make sure to use the measured and calculated shim rings in the correct position.
  83. Install 3 NEW bearing cups (1, 4) to the transmission case on the respective positions, using DT-60000-105  installer (3) and DT-523-1  handle (2). Hammer the outer ring completely into the clutch housing till a clarion, metallic sound is to hear.
    Fig 46: Identifying Bearing Cups
    GM4088056Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The bearing cups were previously marked.

    • I = Input shaft
    • II = Upper main shaft
    • III = Lower main shaft
  84. Remove the transmission case (1) from the DT-60000-130  support (3).
    Fig 47: Identifying Transmission Case, DT-60000-130 Support, Washers And Nuts
    GM4081157Courtesy of GENERAL MOTORS COMPANY
scientia non olet · About LEMON Manuals