Transmission Disassemble

Tools Required

• J 8614-01  Flange and Pulley Holding Tool
• J 22912-01  Split-Plate Bearing Puller
• J 38805  Output Shaft Nut Socket - 4WD only. See Special Tools .
• J 44707  T-Bar Push Puller
• J 45545  Adapter 3/8 inch NF to 5/8 inch NF

IMPORTANT: In order to remove the shift tower, the transmission must be in neutral.
1. Shift the transmission to neutral.
2. Remove the bolts that secure the shift lever to the transmission.
3. Remove the shift lever and shift tower spacer.
   Fig 1: Removing Shift Lever And Shift Tower Spacer

   Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Note the location of the brackets on the shift cover bolts in order to reinstall them in the correct location.
4. Remove the bolts that secure the shift cover to the transmission.
5. Using screwdrivers in the transmission case slots, pry the shift cover from the transmission.
   Fig 2: Prying Shift Cover From Transmission

   Courtesy of GENERAL MOTORS CORP.
6. Using the J 8614-01  to hold the propeller shaft yoke, loosen the mainshaft nut.
   Fig 3: Using J 8614-01 To Loosen Mainshaft Nut

   Courtesy of GENERAL MOTORS CORP.
7. For C model, remove the following parts:
   1. The mainshaft nut
   2. The washer and discard
   3. The rubber washer and discard
   4. The yoke assembly
   Fig 4: Removing Yoke Assembly (C Models)

   Courtesy of GENERAL MOTORS CORP.
8. For C model, remove the vehicle speed sensor and the O-ring seal.
   Fig 5: Removing The VSS And Seal (C Models)

   Courtesy of GENERAL MOTORS CORP.
9. For K model, remove the transmission extension bolts.
10. Remove the transmission extension.
    Fig 6: Removing Transmission Extension (K Models)

    Courtesy of GENERAL MOTORS CORP.
11. For C model, remove the transmission extension bolts.
    Fig 7: Removing Transmission Extension (C Models)

    Courtesy of GENERAL MOTORS CORP.
12. Remove the transmission extension.
13. For K model, using the J 38805  (1), remove the mainshaft nut and washer. See Special Tools .
    Fig 8: Removing Mainshaft Nut & Washer (K Models)

    Courtesy of GENERAL MOTORS CORP.
14. Discard the washer.
IMPORTANT: Use the correct size punch when removing the shift fork roll pins. If the punch is too large, it may flare the shaft rail and cause hard removal of the shift fork.
Fig 9: Removing Overdrive Gear Shift Fork Roll Pins
Courtesy of GENERAL MOTORS CORP.
15. Remove the overdrive gear shift fork roll pins.
16. Remove the overdrive gear retainer ring.
    Fig 10: Removing Overdrive Gear Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
IMPORTANT: For installation alignment, scribe an alignment mark on the synchronizer hubs and synchronizer sleeves before removing. To prevent the synchronizer springs and struts from being lost, do not separate the synchronizer hubs from the synchronizer sleeves. Keep the synchronizer clutch gear and the blocking rings with the synchronizer hubs. Organize the components in order to install the components in their original location and position.
Fig 11: View Of Alignment Marks On Synchronizer Hub & Synchronizer Sleeve
Courtesy of GENERAL MOTORS CORP.
17. Scribe a mark on the overdrive synchronizer hub and synchronizer hub sleeve.
18. Remove the overdrive gear assembly, with the shift fork, from the countershaft.
    Fig 12: Removing Overdrive Gear Assembly

    Courtesy of GENERAL MOTORS CORP.
19. Remove the roller bearing.
20. Remove the thrust washer.
    Fig 13: Removing Thrust Washer

    Courtesy of GENERAL MOTORS CORP.
21. Remove the thrust washer pin from the countershaft.
IMPORTANT: Only remove the vehicle speed sensor during this procedure.
Fig 14: Removing VSS Reluctor (C Models)
Courtesy of GENERAL MOTORS CORP.
22. For C model, remove the vehicle speed sensor reluctor using J 44707  (1), J 45545  (2) and J 22912-01  (3) or equivalent.
23. For C model, remove the mainshaft overdrive gear using J 44707  (1), J 45545  (2) and J 22912-01  (3), or equivalent.
    Fig 15: Removing Mainshaft Overdrive Gear (C Models)

    Courtesy of GENERAL MOTORS CORP.
24. Remove the mainshaft rear bearing retainer bolts.
25. Remove the mainshaft rear bearing retainer.
    Fig 16: Removing Mainshaft Rear Bearing Retainer

    Courtesy of GENERAL MOTORS CORP.
26. Remove the shim or shims.
27. Remove the mainshaft rear bearing cup.
28. Move the synchronizer sleeves into the neutral position.
29. Position the overdrive gear shift lever over to the side and hold in position with a rubber band.
30. For installation alignment, mark the input shaft bearing retainer to the transmission case.
31. Remove the input shaft bearing retainer bolts.
32. Remove the input shaft retainer.
    Fig 17: Removing Input Shaft Bearing Retainer

    Courtesy of GENERAL MOTORS CORP.
33. Remove the input shaft.
    Fig 18: Removing Input Shaft & Main Drive Gear Bearing

    Courtesy of GENERAL MOTORS CORP.
34. Remove the main drive gear bearing.
35. Use the following procedure in order to remove the mainshaft assembly from the case:
    1. Lift the mainshaft and move to the rear of the case.
    2. Tip the front of the mainshaft up and remove the mainshaft from the case.
    Fig 19: Removing Mainshaft Assembly

    Courtesy of GENERAL MOTORS CORP.
36. Remove the countershaft bearing retainer bolts.
37. Remove the countershaft bearing retainer.
    Fig 20: Removing Countershaft Bearing Retainer

    Courtesy of GENERAL MOTORS CORP.
38. Remove the shim or shims.
39. Remove the countershaft rear bearing cup.
40. Remove the reverse idler gear and shaft:
    Fig 21: Removing Reverse Idler Gear & Shaft

    Courtesy of GENERAL MOTORS CORP.
    1. Using a suitable punch, drive the reverse idler gear shaft towards the rear of the case.
    2. Remove the reverse idler gear.
    3. Remove the thrust washers.
    4. Remove the bearing.
41. Remove the countershaft rear bearing using J 44707  (1), J 45545  (2) and J 22912-01  (3), or equivalent.
    Fig 22: Removing Countershaft Rear Bearing

    Courtesy of GENERAL MOTORS CORP.

    Removing the countershaft rear bearing will allow the countershaft to be angled for removal.

42. Remove the countershaft from the transmission case. Slide the countershaft rearward and lift the front of the countershaft out of the case.
    Fig 23: Removing Countershaft

    Courtesy of GENERAL MOTORS CORP.
43. Using a punch or chisel, remove the countershaft front bearing cap.
    Fig 24: Removing Countershaft Front Bearing Cap

    Courtesy of GENERAL MOTORS CORP.
44. Discard the removed bearing cap.
45. Remove the countershaft front bearing cup.
46. Remove the roll pin from the overdrive gear shift lever.
    Fig 25: Removing Overdrive Gear Shift Lever

    Courtesy of GENERAL MOTORS CORP.
47. Remove the shift lever shaft.
48. Remove the overdrive gear shift lever.