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Transmission Assemble

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Special Tools

For equivalent regional tools, refer to Special Tools .

  1. Install the new differential right side oil seal (2) using the DT-51777  seal installer (1).
    Fig 1: Differential Right Side Oil Seal And Special Tool
    GM2493626Courtesy of GENERAL MOTORS COMPANY
    NOTE: Coat the transmission inner parts with gear fluid when installing.
  2. Install the differential right side bearing cup (2) using the DT-50498  differential bearing cup installer (1).
    Fig 2: Differential Right Side Bearing Cup And Special Tool
    GM2493628Courtesy of GENERAL MOTORS COMPANY
  3. Install the NEW input shaft right side seal (2) using the DT-50179  input shaft bearing installer (1).
    Fig 3: Input Shaft Right Side Seal And Special Tool
    GM3970982Courtesy of GENERAL MOTORS COMPANY
  4. Install the differential assembly (1) to the right side of the transmission case. Position the differential ring gear surface lower than the right side of the transmission case surface.
    Fig 4: Differential Assembly
    GM3970963Courtesy of GENERAL MOTORS COMPANY
    NOTE: Rotate the differential assembly on an axis more 10 times after installed the differential assembly.
  5. Install the differential left side bearing cup (1) to the differential left side bearing.
    Fig 5: Measuring To Determine Correct Shim Thickness Needed
    GM2833125Courtesy of GENERAL MOTORS COMPANY
    NOTE: The correct shim must be selected using the following procedure.
  6. Check the transmission right side case surface horizontally with dial gauge.
  7. Measure the height between the transmission right side case surface and the top of the differential left side bearing cup at 3 points then calculate the its average value (L1).
  8. Remove the differential left side bearing cup (1) from the differential left side bearing.
  9. Adjust the transmission left side case surface horizontally using the DT-50501  housing fixing (1) and the dial gauge.
    Fig 6: Measuring To Determine Correct Shim Thickness Needed
    GM2493647Courtesy of GENERAL MOTORS COMPANY
  10. Measure the depth between the transmission left side case surface and the bottom of the differential left side bearing cup seat at 3 points then calculate the average value (L2).
  11. Use the following formula to determine L3; L3 = L2 - L1.
  12. Select the shim to meet the measured value (L3). Refer to Front Differential Bearing Shim Table in Manual Transmission Specifications .
  13. Install the differential left side bearing shim (3).
    Fig 7: Correct Differential Left Side Bearing Shim, Bearing Cup And Special Tool
    GM2493648Courtesy of GENERAL MOTORS COMPANY
  14. Install the differential left side bearing cup (2) using the DT-50498  differential bearing cup installer (1).
  15. Install the New differential left side oil seal (2) using the DT-51777  seal installer (1).
    Fig 8: Differential Left Side Oil Seal And Special Tool
    GM2493649Courtesy of GENERAL MOTORS COMPANY
  16. Install the oil gutter (1).
    Fig 9: Oil Gutter
    GM3970964Courtesy of GENERAL MOTORS COMPANY
  17. Install the low and the high speed shift shaft assembly to the gear unit.
    Fig 10: Gear Unit And Shift Shaft Assembly
    GM3970962Courtesy of GENERAL MOTORS COMPANY
  18. Push the gear unit (1) by matching the unit with the input and the counter shaft hole.
    NOTE: Do not damage the teeth of the counter shaft pinion and the differential ring gear.
  19. Install the 5th and reverse gear shift shaft (1).
    Fig 11: 5th And Reverse Gear Shift Shaft
    GM3970246Courtesy of GENERAL MOTORS COMPANY
  20. Install the reverse idle gear shaft assembly (1).
    Fig 12: Reverse Idle Gear Shaft Assembly
    GM2493651Courtesy of GENERAL MOTORS COMPANY
    NOTE: Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transmission case - right side.
  21. Install the reverse gear shift lever (3).
    Fig 13: Reverse Gear Shift Lever, Washer And Bolts
    GM3970244Courtesy of GENERAL MOTORS COMPANY
  22. Install the reverse gear shift lever washer (2) and bolts (1) and tighten to 23 N.m (17 lb ft).
    CAUTION: Refer to Fastener Caution .
  23. Coat the transmission case with recommended Transmission Case Sealant - THREE BOND 1215 or LOCTITE 5702.
    Fig 14: Left Side Case
    GM3970243Courtesy of GENERAL MOTORS COMPANY
  24. Install transmission left side case (1) to the transmission right side case.
  25. Install the reverse idle gear shaft washer (2) and bolt (1) and tighten to 33 N.m (24 lb ft).
    Fig 15: Reverse Idle Gear Shaft Bolt And Gasket
    GM3970236Courtesy of GENERAL MOTORS COMPANY
  26. Install the new shift shaft detent (1) using a hammer.
    Fig 16: Shift Shaft Detents
    GM3970983Courtesy of GENERAL MOTORS COMPANY
  27. Install 12 bolts (1) into the left case side and tighten to 31 N.m (23 lb ft).
    Fig 17: Left Case Side Bolts
    GM3970240Courtesy of GENERAL MOTORS COMPANY
  28. Install the sensor connector bracket (2) to the left case side.
  29. Install the 2 bolts (1) to the right side case and tighten to 31 N.m (23 lb ft).
    Fig 18: Right Case Side Bolts
    GM2308565Courtesy of GENERAL MOTORS COMPANY
  30. Install the counter shaft bearing cup (2) using the DT-50504  remover/installer (1).
    Fig 19: Counter Shaft Bearing Cup And Special Tool
    GM2833127Courtesy of GENERAL MOTORS COMPANY
    NOTE: Check if the bearing and the cup are correctly installed by rotating counter shaft.
  31. Coat the shift control housing with recommended Shift Control Housing Sealant -THREE BOND 1215 or LOCTITE 5702.
    Fig 20: Shift Control Housing Assembly And Bolts
    GM3970239Courtesy of GENERAL MOTORS COMPANY
    NOTE: Shift the transmission into NEUTRAL.
  32. Install the shift control housing assembly (2).
  33. Install the 4 shift control housing bolts (1) and tighten to 23 N.m (17 lb ft).
  34. Install the shift interlock washer (2) and bolt (1) and tighten to 23 N.m (17 lb ft).
    Fig 21: Shift Interlock Washer And Bolt
    GM3970238Courtesy of GENERAL MOTORS COMPANY
  35. Measure the clearance between the transmission case surface (3) and the bearing cup (2) using a straight ruler (1) and a gauge.
    Fig 22: Measuring To Determine Correct Shim Thickness Needed
    GM2569298Courtesy of GENERAL MOTORS COMPANY
  36. Select a shim so that clearance is within standard. Refer to Manual Transmission Specifications .
  37. Install the counter shaft bearing shim (3).
    Fig 23: Left Case Plate, Shim And Screws
    GM2308511Courtesy of GENERAL MOTORS COMPANY
  38. Install the left case plate (2).
  39. Install the 6 New left case plate screws (1) and tighten to 9 N.m (80 lb in).
  40. Install the countershaft 5th gear (2) using the DT-49080  gear, bearing installer (1).
    Fig 24: Countershaft 5th Gear And Special Tool
    GM2754229Courtesy of GENERAL MOTORS COMPANY
    NOTE: Position the machined boss side toward the side cover plate.
  41. Insert the input shaft 5th gear bearing (1) into the input shaft.
    Fig 25: Input Shaft 5th Gear And Bearing
    GM2308508Courtesy of GENERAL MOTORS COMPANY
  42. Install the input shaft 5th gear (2).
  43. Install the synchronizer ring (1).
    Fig 26: 5th Gear Synchronizer Hub Components
    GM3970234Courtesy of GENERAL MOTORS COMPANY
  44. Install the lever marks side toward outer side and install the levers (2).
    NOTE: Make sure that the lever mark must be showed after installation.
  45. Install the longer boss side of hub (3) toward inner side.
  46. Install the 5th gear synchronizer hub plate (4) into the hub (3).
  47. Install the 5th gear fork (1) and the synchronizer sleeve (2) together.
    Fig 27: 5th Gear Fork And Synchronizer Sleeve
    GM3970233Courtesy of GENERAL MOTORS COMPANY
  48. Install the new 5th gear shift fork pin (1) using a pin punch and a hammer.
    Fig 28: 5th Gear Shift Fork Pin
    GM3970231Courtesy of GENERAL MOTORS COMPANY
    NOTE: Align the 5th gear fork hole with the 5th reverse gear shaft hole before installing the 5th gear shift fork pin.
  49. Install the new input shaft circlip (1).
    Fig 29: Input Shaft Circlip
    GM2754425Courtesy of GENERAL MOTORS COMPANY
  50. Move the shift shaft lever into the 5th gear position.
    Fig 30: Holding Input Shaft Using DT-49084
    GM2308586Courtesy of GENERAL MOTORS COMPANY
  51. Hold the input shaft using the DT-49084  input shaft holder (1).
  52. Install the new countershaft nut and tighten to 70 N.m (52 lb ft).
  53. Caulk the nut using a chisel and hammer.
  54. Coat the side cover with recommended Side Cover Sealant-THREE BOND 1215 or LOCTITE 5702.
    Fig 31: Side Cover Bolts
    GM2308498Courtesy of GENERAL MOTORS COMPANY
  55. Install the side cover (2).
  56. Install 8 side cover bolts (1) and tighten to 10 N.m (89 lb in).
  57. Install the clutch actuator cylinder (2).
    Fig 32: Clutch Actuator Cylinder And Bolts
    GM3970229Courtesy of GENERAL MOTORS COMPANY
  58. Install the 3 clutch actuator cylinder bolts (1) and tighten to 9 N.m (80 lb in)
  59. Install the clutch actuator cylinder pipe sleeve (3) into the clutch actuator cylinder pipe (2).
    Fig 33: Clutch Actuator Cylinder Components
    GM3970227Courtesy of GENERAL MOTORS COMPANY
  60. Install the clutch actuator cylinder pipe (2) with sleeve (3) into transmission right side case.
  61. Install the clutch actuator cylinder pipe (2) into the clutch actuator cylinder.
  62. Install the clutch actuator cylinder clip (1).
  63. Install the clutch actuator cylinder pipe elbow (2).
    Fig 34: Clutch Actuator Cylinder Pipe Elbow And Clip
    GM3970226Courtesy of GENERAL MOTORS COMPANY
  64. Install the clutch actuator cylinder pipe elbow clip (1).
  65. If equipped, install the input speed sensor (2).
    Fig 35: Input Speed Sensor And Bolt
    GM4646448Courtesy of GENERAL MOTORS COMPANY
  66. If equipped, install the input speed sensor bolt (1) and tighten to 9 N.m (80 lb in).
  67. If equipped, install the vehicle speed sensor assembly (2).
    Fig 36: Vehicle Speed Sensor Assembly And Bolt
    GM3970225Courtesy of GENERAL MOTORS COMPANY
  68. If equipped, install the vehicle speed sensor assembly bolt (1) and tighten to 9 N.m (80 lb in).
  69. Install the backup light switch (2) using the DT-50182  backup light switch remover/installer (1) and tighten to 17 N.m (13 lb ft).
    Fig 37: Backup Light Switch And Special Tool
    GM3970224Courtesy of GENERAL MOTORS COMPANY
  70. Install the selector and shift lever cable bracket (2).
    Fig 38: Selector And Shift Lever Cable Bracket And Bolts
    GM3970223Courtesy of GENERAL MOTORS COMPANY
  71. Install the selector and shift lever cable bracket bolts (1) and tighten to 20 N.m (15 lb ft).
  72. Install the transmission assembly. Refer to Transmission Replacement (With 1.0L Engine) Transmission Replacement (With 1.4L Engine) .
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