Transmission Disassemble

WARNING: This page is about a different car, the 2017 Chevrolet Spark. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools

DT-586 Universal Seal Remover
DT-7004 Sliding Hammer
DT-49084 Input Shaft Holder
DT-50182 Backup Light Switch Remover/Installer
DT-50500 Differential Bearing Cup Remover
DT-50504 Counter Shaft Bearing Cup Remover/Installer
DT-50505 Bridge
DT-727 Remover
GE-328 - B Puller

For equivalent regional tools, refer to Special Tools .

Remove the manual transmission. Refer to Transmission Replacement (With 1.0L Engine) Transmission Replacement (With 1.4L Engine) .
Remove the selector and shift lever cable bracket bolts (1).

Fig 1: Selector And Shift Lever Cable Bracket And Bolts
Courtesy of GENERAL MOTORS COMPANY
Remove the selector and shift lever cable bracket (2).
Remove the backup light switch (2) using the DT-50182 backup lamp switch remover/installer (1).

Fig 2: Backup Light Switch And Special Tool
Courtesy of GENERAL MOTORS COMPANY
If equipped, remove the vehicle speed sensor assembly bolt (1).

Fig 3: Vehicle Speed Sensor Assembly And Bolt
Courtesy of GENERAL MOTORS COMPANY
If equipped, remove the vehicle speed sensor assembly (2).
If equipped, remove the input speed sensor bolt (1).

Fig 4: Input Speed Sensor And Bolt
Courtesy of GENERAL MOTORS COMPANY
If equipped, remove the input speed sensor (2).
Remove the clutch actuator cylinder pipe elbow clip (1).

Fig 5: Clutch Actuator Cylinder Pipe Elbow And Clip
Courtesy of GENERAL MOTORS COMPANY
Remove the clutch actuator cylinder pipe elbow (2).
Remove the clutch actuator cylinder clip (1).

Fig 6: Clutch Actuator Cylinder Components
Courtesy of GENERAL MOTORS COMPANY
Remove the clutch actuator cylinder pipe (2) and sleeve (3) from transmission right side case.
Remove the clutch actuator cylinder pipe sleeve (3) from the clutch actuator cylinder pipe.
NOTE: Push the key (4) of the clutch actuator cylinder pipe sleeve using a screw driver.
Remove the 3 clutch actuator cylinder bolts (1).

Fig 7: Clutch Actuator Cylinder And Bolts
Courtesy of GENERAL MOTORS COMPANY
Remove the clutch actuator cylinder (2).
Remove 8 side cover bolts (1).

Fig 8: Side Cover Bolts
Courtesy of GENERAL MOTORS COMPANY
Remove side cover (2) using a rubber hammer.
Remove the sealant on the side cover and the transmission case.
Remove the input shaft circlip (1).

Fig 9: Input Shaft Circlip
Courtesy of GENERAL MOTORS COMPANY
Remove the 5th gear shift fork pin (1) using a pin punch and a hammer.

Fig 10: 5th Gear Shift Fork Pin
Courtesy of GENERAL MOTORS COMPANY
Pull and remove the 5th gear fork (1) and the synchronizer sleeve (2) together.

Fig 11: 5th Gear Fork And Synchronizer Sleeve
Courtesy of GENERAL MOTORS COMPANY
Remove the 5th gear synchronizer hub plate (4) from the 5th synchronizer hub.

Fig 12: 5th Gear Synchronizer Hub Components
Courtesy of GENERAL MOTORS COMPANY
Remove the 5th synchronizer hub (3), 2 levers (2) and the synchronizer ring (1).
Pull and remove the input shaft 5th gear (1).

Fig 13: Input Shaft 5th Gear And Bearing
Courtesy of GENERAL MOTORS COMPANY
Remove the input shaft 5th gear bearing (2).
Hold the input shaft using the DT-49084 input shaft holder (1).

Fig 14: View Of DT-49084 Input Shaft Holder
Courtesy of GENERAL MOTORS COMPANY
Remove the caulking and the counter shaft 5th gear nut (2).
Remove the counter shaft 5th gear (1) from the counter shaft.

Fig 15: Counter Shaft 5th Gear
Courtesy of GENERAL MOTORS COMPANY
Remove 6 left case plate screws (1).

Fig 16: Left Case Plate, Shim And Screws
Courtesy of GENERAL MOTORS COMPANY
Remove the left case plate (2).
Remove the countershaft bearing shim (3).
Remove the reverse idle gear shaft bolt (1) and gasket (2).

Fig 17: Reverse Idle Gear Shaft Bolt And Gasket
Courtesy of GENERAL MOTORS COMPANY

NOTE: The case (Left) cannot be removed without removing the reverse idle gear shaft bolt.
Remove the shift interlock washer (2) and bolt (1).

Fig 18: Shift Interlock Washer And Bolt
Courtesy of GENERAL MOTORS COMPANY

NOTE: Certainly remove the shift interlock bolt. Otherwise, shift control housing assembly cannot be removed.
Remove the 4 shift control housing bolts (1).

Fig 19: Shift Control Housing Assembly And Bolts
Courtesy of GENERAL MOTORS COMPANY

NOTE: Shift the transmission into NEUTRAL.
Remove the shift control housing assembly (2).
Remove the sealant on the shift control housing and the transmission case.
Remove the 2 bolts (1) from the right case side.

Fig 20: Right Case Side Bolts
Courtesy of GENERAL MOTORS COMPANY
Remove 13 bolts (1) from the left case side.

Fig 21: Left Case Side Bolts
Courtesy of GENERAL MOTORS COMPANY
Remove the shift shaft detent (3) using the DT-727 remover (1) and GE-328 - B Puller (2).

Fig 22: Shift Shaft Detent And Special Tools
Courtesy of GENERAL MOTORS COMPANY

NOTE: Inspect the detent for damage. If the detent is damaged, remove and discard the detent.
Remove the left side case by hitting with a rubber hammer lightly.

Fig 23: Left Side Case
Courtesy of GENERAL MOTORS COMPANY
Remove the sealant on the case.
Remove the reverse gear shift lever washer (2) and bolts (1).

Fig 24: Reverse Gear Shift Lever, Washer And Bolts
Courtesy of GENERAL MOTORS COMPANY
Remove the reverse gear shift lever (3).
Remove the reverse idle gear (2) and shaft (1).

Fig 25: Reverse Idle Gear And Shaft
Courtesy of GENERAL MOTORS COMPANY
Remove the reverse idle gear (2) from the shaft assembly.
Remove the 5th and reverse gear shift shaft (1).

Fig 26: 5th And Reverse Gear Shift Shaft
Courtesy of GENERAL MOTORS COMPANY
Remove the gear unit and the shift shaft assembly (1) together.

Fig 27: Gear Unit And Shift Shaft Assembly
Courtesy of GENERAL MOTORS COMPANY

NOTE: Be careful not to damage the teeth of the counter shaft pinion and the differential ring gear.
Remove the high and the low speed shift shaft assembly from the gear unit.
Insert a wooden prying device into the lower side of the differential.

Fig 28: Differential Assembly
Courtesy of GENERAL MOTORS COMPANY
Remove the differential assembly (1) by moving it right and left.
Remove the oil gutter (1).

Fig 29: Oil Gutter
Courtesy of GENERAL MOTORS COMPANY

NOTE: Push the key of the oil gutter from the left side case using a screw driver.
Remove the counter shaft bearing cup (2) using the DT-50504 counter shaft bearing cup remover/installer (1) and a hammer.

Fig 30: Counter Shaft Bearing Cup And Special Tool
Courtesy of GENERAL MOTORS COMPANY
Remove the differential left side bearing cup (3) using the DT-50500 differential bearing cup remover (1) and the DT-50505 bridge (2).

Fig 31: Differential Left Side Bearing Cup, Left Side Bearing Shim And Special Tools
Courtesy of GENERAL MOTORS COMPANY
Remove the differential left side bearing shim (4).
Remove the differential right side oil seal (1) using the DT-7004 sliding hammer and the DT-586 seal remover hook (2).

Fig 32: Differential Right Side Oil Seal And Special Tools
Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not reuse the differential right side oil seal.
Remove the input shaft right side seal (1) using a screwdriver.

Fig 33: Input Shaft Right Side Seal
Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not reuse the input shaft right side seal.
Remove the differential right side bearing cup (3) using the DT-50500 differential bearing cup remover (1) and the DT-50505 bridge (2).

Fig 34: Differential Right Side Bearing Cup And Special Tools
Courtesy of GENERAL MOTORS COMPANY
Remove the differential left side oil seal (1) using the DT-586 seal remover hook (2) and DT-7004 sliding hammer (3).

Fig 35: Differential Left Side Oil Seal And Special Tools
Courtesy of GENERAL MOTORS COMPANY

NOTE: Do not reuse the differential left side oil seal.