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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1159 (Manual Transmission - AISIN AY6) >> Repair Instructions - Off Vehicle >> Transmission Disassemble >> Procedures

Transmission Disassemble: Procedures

WARNING: This page is about a different car, the 2008 Cadillac CTS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of DT-47678 And Transmission Clutch Housing
    GM1921421Courtesy of GENERAL MOTORS CORP.
  1. Install DT-47678  (2) to the transmission clutch housing. See Special Tools .
  2. Mount the transmission to a workbench using J 3289-20  (1).
  3. Remove the clutch release cylinder bolts and the clutch release cylinder. Refer to Clutch Concentric Actuator Cylinder Replacement (CTS) .
    4. Fig 2: Identifying Fill Plug, Drain Plug And Washer
    GM1921433Courtesy of GENERAL MOTORS CORP.
  4. Remove the fill plug (79) and the washer (33).
  5. Remove the drain plug (34) and the washer (33) then drain the transmission fluid.
    6. Fig 3: Identifying Backup Lamp Switch And Washer
    GM1921436Courtesy of GENERAL MOTORS CORP.
  6. Remove the backup lamp switch and washer (208) from the case.
    7. Fig 4: View Of Output Sensor And Bolt
    GM1921440Courtesy of GENERAL MOTORS CORP.
  7. Remove the output sensor (213) and bolt (215) from the rear extension housing.
    8. Fig 5: View Shift Lever Pin Shift Lever Retainer
    GM1998287Courtesy of GENERAL MOTORS CORP.
    NOTE: When releasing the staking, do not tap with a hammer. Excessive force may damage the bearing.
  8. To release the staking, insert a screwdriver into the gap between the select shift lever retainer (42) and the rod.
  9. With suitable pliers, rotate the select shift lever retainer (42) forward.
  10. Use a magnet to remove the shift lever pin (41).
    11. Fig 6: Identifying Shift Lever Rod Universal Joint, Damper And Shift Lever Retainer
    GM1998288Courtesy of GENERAL MOTORS CORP.
  11. Remove the shift lever rod universal joint (40), damper (102) and select shift lever retainer (42) from the end of the shift selector.
    12. Fig 7: Identifying Propshaft Flange Nut, Propshaft Flange Fluid Seal And Propshaft Flange
    GM1921441Courtesy of GENERAL MOTORS CORP.
  12. Using a screwdriver, release the staking of the propshaft flange nut (126).
  13. Remove the propshaft flange nut (126) and propshaft flange fluid seal (193).
  14. Remove the propshaft flange (108).
    15. Fig 8: Identifying Bolts and Extension Housing
    GM1921442Courtesy of GENERAL MOTORS CORP.
  15. Remove the 8 bolts (93) from the extension housing (86).
  16. Remove the extension housing.
    17. Fig 9: View Of Vehicle Speed Sensor Drive Gear, Spacer, Locking Ball & Main Shaft Bearing Oil Slinger
    GM1413895Courtesy of GENERAL MOTORS CORP.
  17. Remove the rear output shaft rear bearing spacer (191).
  18. Remove the vehicle speed sensor drive gear (212).
  19. Remove the locking ball (214).
  20. Remove the main shaft bearing oil slinger (107).
    21. Fig 10: Removing/Installing Clutch Housing Hole Plug
    GM1413898Courtesy of GENERAL MOTORS CORP.
  21. Remove the clutch housing hole plug (30) from the clutch housing.
    22. Fig 11: View Of Shift Shaft Detent Plug, Spring & Pin
    GM1504121Courtesy of GENERAL MOTORS CORP.
  22. Remove the following components:
    • The shift shaft detent plug (36)
    • The shift shaft detent spring (75)
    • The shift shaft detent pin (68)
    23. Fig 12: View Of Rear Case Housing Retainer & Bolts
    GM1413899Courtesy of GENERAL MOTORS CORP.
  23. Remove the 10 bolts (27) and retainer (209) from the rear case housing.
    24. NOTE: Refer to Machined Surface Damage Notice .
  24. Using a soft-face hammer, separate the rear case housing from the intermediate case housing.
  25. Remove the rear case housing.
    26. Fig 13: View Of Oil Trough Bolts And Oil Trough
    GM1413901Courtesy of GENERAL MOTORS CORP.
  26. Remove the 2 oil trough bolts (37) and oil trough (20).
    27. Fig 14: View Of Oil Trough Pipe, Bolt & Gasket
    GM1504123Courtesy of GENERAL MOTORS CORP.
  27. Remove the oil trough pipe (19).
  28. Remove the reverse idler gear shaft bolt (35) and gasket (32).
    29. Fig 15: View Of Clutch Housing Bolts
    GM1413897Courtesy of GENERAL MOTORS CORP.
  29. Remove the 11 flange bolts retaining the clutch housing. This includes 8 bolts from the front and 3 bolts from the rear.
    30. Fig 16: View Of Intermediate Case Housing
    GM1413902Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Machined Surface Damage Notice .
  30. Using a soft-face hammer, separate the intermediate case from the front clutch housing.
  31. Remove the intermediate case housing.
    32. Fig 17: View Of Shift Shaft Selector Lever
    GM1413904Courtesy of GENERAL MOTORS CORP.
  32. Remove the shift shaft selector lever.
    33. Fig 18: View Of Rear Output Shaft, Input Shaft Bearing & Blocking Ring
    GM1413910Courtesy of GENERAL MOTORS CORP.
  33. Remove the rear output shaft (111), input shaft bearing (137) and blocking ring (121) from the 6th gear synchronizer assembly.
    34. Fig 19: View Of Reverse Idler Gear, Bearing & Shaft
    GM1413905Courtesy of GENERAL MOTORS CORP.
  34. Remove the reverse idler gear bearing (136), reverse idler gear (205) and the reverse idler gear shaft (204).
    35. Fig 20: View Of Shift Counter Lever Bracket Bolts
    GM1425647Courtesy of GENERAL MOTORS CORP.
  35. Remove the 4 bracket bolts from the shift counter lever bracket.
    36. Fig 21: Removing/Installing Front Countershaft Bearing Snap Ring
    GM1413907Courtesy of GENERAL MOTORS CORP.
  36. Stretch snap ring on the front countershaft bearing. Maintain stretch.
    37. Fig 22: Tapping Transmission Front Case To Disengage Snap Ring
    GM1425649Courtesy of GENERAL MOTORS CORP.
  37. Using a rubber hammer, tap on transmission front case in order to disengage the countershaft bearing's snap ring.
    38. Fig 23: Removing/Installing Rear Input Shaft Bearing Snap Ring
    GM1413909Courtesy of GENERAL MOTORS CORP.
  38. Stretch the snap ring on the rear input shaft bearing. Maintain stretch.
    39. Fig 24: Tapping Transmission Front Case To Disengage Snap Ring
    GM1425649Courtesy of GENERAL MOTORS CORP.
  39. Hold the countershaft. Using a soft rubber hammer tap on the transmission front case in order to disengage the snap ring. Separate the input shaft and countershaft from clutch housing.
    40. Fig 25: View Of Input Shaft, Countershaft & Shift Rail Assembly
    GM1425650Courtesy of GENERAL MOTORS CORP.
  40. Remove the input shaft, countershaft and shift rails as an assembly.
    41. Fig 26: Disassembling/Assembling Shift Rails, Input Shaft & Countershaft
    GM1425652Courtesy of GENERAL MOTORS CORP.
  41. Separate the shift rails, the input shaft and countershaft.
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