LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2018 >> Spark LT, Automatic CVT Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Manual Transmission - Y4A/Y4M) >> Repair Instructions - Off Vehicle >> Transmission Assemble

Transmission Assemble

WARNING: This page is about a different variant/trim than selected.

Special Tools

For equivalent regional tools, refer to Special Tools .

  1. GM2493626Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Coat the transmission inner parts with gear fluid when installing.

    Install the new differential right side oil seal (2) using the DT-51777  seal installer (1).

  2. GM2493628Courtesy of GENERAL MOTORS COMPANY

    Install the differential right side bearing cup (2) using the DT-50498  differential bearing cup installer (1).

  3. GM3970982Courtesy of GENERAL MOTORS COMPANY

    Install the NEW input shaft right side seal (2) using the DT-50179  input shaft bearing installer (1).

  4. GM3970963Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Rotate the differential assembly on an axis more 10 times after installed the differential assembly.

    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.

  5. GM2833125Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The correct shim must be selected using the following procedure.

    Install the differential left side bearing cup (1) to the differential left side bearing.

  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. GM2493647Courtesy of GENERAL MOTORS COMPANY

    Adjust the transmission left side case surface horizontally using the DT-50501  housing fixing (1) and the dial gauge.

  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. GM2493648Courtesy of GENERAL MOTORS COMPANY

    Install the differential left side bearing shim (3).

  14. Install the differential left side bearing cup (2) using the DT-50498  differential bearing cup installer (1).
  15. GM2493649Courtesy of GENERAL MOTORS COMPANY

    Install the New differential left side oil seal (2) using the DT-51777  seal installer (1).

  16. GM3970964Courtesy of GENERAL MOTORS COMPANY

    Install the oil gutter (1).

  17. GM3970962Courtesy of GENERAL MOTORS COMPANY

    Install the low and the high speed shift shaft assembly to the gear unit.

    18. NOTE:

    Do not damage the teeth of the counter shaft pinion and the differential ring gear.

  18. Push the gear unit (1) by matching the unit with the input and the counter shaft hole.
  19. GM3970246Courtesy of GENERAL MOTORS COMPANY

    Install the 5th and reverse gear shift shaft (1).

  20. 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.

    Install the reverse idle gear shaft assembly (1).

  21. GM3970244Courtesy of GENERAL MOTORS COMPANY

    Install the reverse gear shift lever (3).

    22. CAUTION:

    Refer to Fastener Caution .

  22. Install the reverse gear shift lever washer (2) and bolts (1) and tighten to 23 N.m (17 lb ft).
  23. GM3970243Courtesy of GENERAL MOTORS COMPANY

    Coat the transmission case with recommended Transmission Case Sealant - THREE BOND 1215 or LOCTITE 5702.

  24. Install transmission left side case (1) to the transmission right side case.
  25. GM3970236Courtesy of GENERAL MOTORS COMPANY

    Install the reverse idle gear shaft washer (2) and bolt (1) and tighten to 33 N.m (24 lb ft).

  26. GM3970983Courtesy of GENERAL MOTORS COMPANY

    Install the new shift shaft detent (1) using a hammer.

  27. GM3970240Courtesy of GENERAL MOTORS COMPANY

    Install 12 bolts (1) into the left case side and tighten to 31 N.m (23 lb ft).

  28. Install the sensor connector bracket (2) to the left case side.
  29. GM2308565Courtesy of GENERAL MOTORS COMPANY

    Install the 2 bolts (1) to the right side case and tighten to 31 N.m (23 lb ft).

  30. GM2833127Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Check if the bearing and the cup are correctly installed by rotating counter shaft.

    Install the counter shaft bearing cup (2) using the DT-50504  remover/installer (1).

  31. GM3970239Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Shift the transmission into NEUTRAL.

    Coat the shift control housing with recommended Shift Control Housing Sealant -THREE BOND 1215 or LOCTITE 5702.

  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. GM3970238Courtesy of GENERAL MOTORS COMPANY

    Install the shift interlock washer (2) and bolt (1) and tighten to 23 N.m (17 lb ft).

  35. GM2569298Courtesy of GENERAL MOTORS COMPANY

    Measure the clearance between the transmission case surface (3) and the bearing cup (2) using a straight ruler (1) and a gauge.

  36. Select a shim so that clearance is within standard. Refer to Manual Transmission Specifications .
  37. GM2308511Courtesy of GENERAL MOTORS COMPANY

    Install the counter shaft bearing shim (3).

  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. GM2754229Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Position the machined boss side toward the side cover plate.

    Install the countershaft 5th gear (2) using the DT-49080  gear, bearing installer (1).

  41. GM2308508Courtesy of GENERAL MOTORS COMPANY

    Insert the input shaft 5th gear bearing (1) into the input shaft.

  42. Install the input shaft 5th gear (2).
  43. Fig 1: Exploded View Of 5th Gear Synchronizer Hub Components
    GM3970234Courtesy of GENERAL MOTORS COMPANY

    Install the synchronizer ring (1).

    44. NOTE:

    Make sure that the lever mark must be showed after installation.

  44. Install the lever marks side toward outer side and install the levers (2).
  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. GM3970233Courtesy of GENERAL MOTORS COMPANY

    Install the 5th gear fork (1) and the synchronizer sleeve (2) together.

  48. 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.

    Install the new 5th gear shift fork pin (1) using a pin punch and a hammer.

  49. GM2754425Courtesy of GENERAL MOTORS COMPANY

    Install the new input shaft circlip (1).

  50. GM2308586Courtesy of GENERAL MOTORS COMPANY

    Move the shift shaft lever into the 5th gear position.

  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. GM2308498Courtesy of GENERAL MOTORS COMPANY

    Coat the side cover with recommended Side Cover Sealant-THREE BOND 1215 or LOCTITE 5702.

  55. Install the side cover (2).
  56. Install 8 side cover bolts (1) and tighten to 10 N.m (89 lb in).
  57. GM3970229Courtesy of GENERAL MOTORS COMPANY

    Install the clutch actuator cylinder (2).

  58. Install the 3 clutch actuator cylinder bolts (1) and tighten to 9 N.m (80 lb in)
  59. GM3970227Courtesy of GENERAL MOTORS COMPANY

    Install the clutch actuator cylinder pipe sleeve (3) into the clutch actuator cylinder pipe (2).

  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. GM3970226Courtesy of GENERAL MOTORS COMPANY

    Install the clutch actuator cylinder pipe elbow (2).

  64. Install the clutch actuator cylinder pipe elbow clip (1).
  65. GM4646448Courtesy of GENERAL MOTORS COMPANY

    If equipped, install the input speed sensor (2).

  66. If equipped, install the input speed sensor bolt (1) and tighten to 9 N.m (80 lb in).
  67. GM3970225Courtesy of GENERAL MOTORS COMPANY

    If equipped, install the vehicle speed sensor assembly (2).

  68. If equipped, install the vehicle speed sensor assembly bolt (1) and tighten to 9 N.m (80 lb in).
  69. GM3970224Courtesy of GENERAL MOTORS COMPANY

    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).

  70. GM3970223Courtesy of GENERAL MOTORS COMPANY

    Install the selector and shift lever cable bracket (2).

  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) .
scientia non olet · About LEMON Manuals