Mainshaft Assemble

Tools Required

• J 6133-A  Bearing Race Installer
• J 22873  Slide Hammer
• J 36184  Press Tube Adapter
• J 36373  Input Gear Ball Bearing Installer
• J 36515  Assembly Pallet. See Special Tools .
• J 36515-15  Mainshaft Adapter. See Special Tools .
• J 36515-16  Countershaft Adapter. See Special Tools .
• J 36850  TRANSJEL Lubricant
• J 39924-1  Reverse Drag Seal Installer. See Special Tools .
• J 39924-2  5th Gear Drag Seal Installer

1. Using the J 39924-1  , install the reverse speed gear drag seal. See Special Tools .
   Fig 1: Installing Reverse Speed Gear Drag Seal

   Courtesy of GENERAL MOTORS CORP.
2. Install the reverse speed gear needle bearing (1).
   Fig 2: Installing Reverse Gear & Needle Bearing Assembly

   Courtesy of GENERAL MOTORS CORP.
3. Lubricate the reverse speed gear bearing with transmission fluid.
4. Install the reverse speed gear (2).
5. Install the 5th/Reverse speed gear synchronizer assembly using a hydraulic press and J 36184  .
   Fig 3: Installing 5th/Reverse Speed Gear Synchronizer Assembly

   Courtesy of GENERAL MOTORS CORP.
   1. Align the groove on the 5th/Reverse synchronizer sleeve towards the reverse gear.
   2. Ensure the reverse synchronizer blocking ring is aligned to the synchronizer hub.
6. Install a new 5th/Reverse synchronizer hub retaining ring.
   Fig 4: Installing 5th/Reverse Synchronizer Hub Retaining Ring

   Courtesy of GENERAL MOTORS CORP.
7. Install the 5th speed gear needle bearing (1).
   Fig 5: Installing 5th Speed Gear, Synchronizer Ring & Needle Bearing Assembly

   Courtesy of GENERAL MOTORS CORP.
8. Lubricate the bearing with transmission fluid.
9. Install the synchronizer ring (2).
10. Install the 5th speed gear (3).
11. Install the 1st speed gear needle bearing assembly.
    Fig 6: Installing 1st Gear Needle Bearing Assembly

    Courtesy of GENERAL MOTORS CORP.
12. Lubricate the bearing with transmission fluid.
IMPORTANT: The groove on the outside of the synchronizer sleeve must go towards the 2nd speed gear. This prevents gear clash during 1st and 2nd speed gear shifts. The teeth of the sleeve have different angles.
Fig 7: Installing 1st Gear & Components
Courtesy of GENERAL MOTORS CORP.
13. Install the following components:
    1. The 1st speed gear (1)
    2. The synchronizer interim ring (2) with the teeth up
    3. The reactor cone (3) with the flat side towards 1st gear
    4. The blocker ring (4) with the teeth down
    5. The synchronizer cone (5) with the flat side down
14. Install the 1st/2nd speed gear synchronizer assembly with both synchronizer rings.
    1. Manually align and engage the splines of the synchronizer hub with the main shaft splines.
    2. Using a hydraulic press, the J 22873  , press the synchronizer hub onto the main shaft.
       Fig 8: Using Press To Install Synchronizer Assembly

       Courtesy of GENERAL MOTORS CORP.
    3. Start the press operation.
       1. Stop pressing before the tangs engage.
       2. Lift and rotate the gear.
       3. Engage the synchronizer ring.
    4. Press the synchronizer until seated.
    5. Remove all the metal shavings.
15. Install the 2nd gear synchronizer interim ring.
    Fig 9: Installing 2nd Gear Synchronizer Interim Ring

    Courtesy of GENERAL MOTORS CORP.
16. Install a new 1st/2nd gear synchronizer retaining ring.
17. Install the following 2nd gear synchronizer components:
    1. The synchronizer cone with the flat up
    2. The blocker ring with the tangs up
    3. The reaction cone with the wide flat portion up
    Fig 10: Installing 2nd Gear Synchronizer Components

    Courtesy of GENERAL MOTORS CORP.
18. Install the 2nd speed gear needle bearing (2).
    Fig 11: Installing 2nd Speed Gear & Needle Bearing

    Courtesy of GENERAL MOTORS CORP.
19. Lubricate the bearing with transmission fluid.
20. Install the 2nd speed gear (1).

    Ensure that the synchronizer ring gear teeth are positioned toward the 1st gear.

21. Install the 2nd speed gear 2 piece thrust washer. Ensure that the dots on the thrust washer are facing up.
    Fig 12: Installing 2nd Speed Gear 2 Piece Thrust Washer

    Courtesy of GENERAL MOTORS CORP.
22. Install the retainer ring. Ensure that the retainer ring is installed around the thrust washers.
23. Install the following components:
    1. The 3rd speed gear needle bearing (1)
    2. The 3rd speed gear (2)
    3. The synchronizer ring (3)
    Fig 13: Installing 3rd Speed Gear Components

    Courtesy of GENERAL MOTORS CORP.
24. Install the 3rd/4th speed gear synchronizer assembly with both synchronizer rings. Ensure that the groove in the synchronizer ring faces upward.
    1. Manually align and engage the splines of the synchronizer hub with the main shaft splines.
    2. Using a hydraulic press, the J 36373  , press the synchronizer hub onto the main shaft.
       Fig 14: Using Press To Install 3rd/4th Gear Synchronizer Hub

       Courtesy of GENERAL MOTORS CORP.
    3. Start the press operation.
       1. Stop pressing before the tangs engage.
       2. Lift and rotate the gear.
       3. Engage the synchronizer ring.
    4. Press the synchronizer until seated.
    5. Remove all the metal shavings.
25. Install a new mainshaft snap ring.
    Fig 15: Installing Mainshaft Snap Ring

    Courtesy of GENERAL MOTORS CORP.
26. Install the input shaft (1) on the assembly fixture J 36515-15  and J 36515  . See Special Tools .
    Fig 16: Installing Input Shaft, Pilot Bearing, Synchronizer Ring & Mainshaft Assembly

    Courtesy of GENERAL MOTORS CORP.
27. Install the pilot bearing (2) in the input shaft (1).
    1. Ensure the small diameter of the bearing is positioned toward the input shaft.
    2. Lubricate the pilot bearing with J 36850  .
28. Install the synchronizer ring (3) on the input shaft (1).
29. Install the mainshaft assembly (4) onto the input shaft (1).
30. Install the following parts on the mainshaft and on the assembly fixture J 36515-16  . See Special Tools .
    1. The countershaft assembly (1)
    2. The reverse idler assembly (2)
    3. The 1st/2nd speed gear shift fork (3)
    4. The 5th/Reverse speed gear shift fork (4)
    Fig 17: Installing Countershaft Assembly, Reverse Idler Assembly, 1st/2nd Gear Shift Fork & 5th Reverse Gear Fork

    Courtesy of GENERAL MOTORS CORP.
31. Install the countershaft bearing on the countershaft.

    Use the J 36850  in order to retain the bearing.

    The smaller diameter of the bearing cage is positioned toward the housing.

32. If 2WD, install the main shaft rear bearing (2) on the main shaft.
    Fig 18: Installing Mainshaft Rear Bearing & Retaining Ring (2WD)

    Courtesy of GENERAL MOTORS CORP.
33. Install a new main shaft rear bearing retaining ring (1).
34. If 2WD, using J 6133-A  , install the reluctor wheel onto the main shaft.
    Fig 19: Installing Reluctor Wheel (2WD)

    Courtesy of GENERAL MOTORS CORP.