Output Shaft Disassemble

Tools Required

• J 8001-3  Dial Indicator
• J 22912-B  Split-Plate Bearing Puller
• J 26900-12  Dial Indicator - 1-10 mm. See Special Tools .
• J 26900-13  Magnetic Indicator Base. See Special Tools .
• J 45869  Gear Protector Plates. See Special Tools .

Fig 1: View Of Speed Sensor Reluctor Wheel Front Retaining Ring, Wheel & Ball
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The following steps apply to both the 4WD and the RWD transmission, except where noted.
1. If RWD, remove the speed sensor reluctor wheel rear retaining ring.
2. Remove the speed sensor reluctor wheel.
3. Remove the speed sensor reluctor wheel locating ball.
4. Remove the speed sensor reluctor wheel front retaining ring.
Fig 2: Measuring 1st Gear Axial Play
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Before disassembly of the output shaft, measure the axial play of the speed gears. If axial play of the speed gears is incorrect, it may cause shifting concerns or transmission noise.
5. Using J 8001-3  or J 26900-12  (1) and J 26900-13  (2), measure the 1st gear axial play. See Special Tools .

   Specification: 

   • Standard Clearance: 0.20-0.45 mm (0.0079-0.0177 in)
   • Maximum Clearance: 0.50 mm (0.0197 in)
   1. Position J 8001-3  or J 26900-12  (1) on the top of the gear teeth. See Special Tools .
   2. Zero the gage.
   3. Lift up on the gear to measure the clearance.
6. If the clearance exceeds the maximum, refer to Gears and Shafts Cleaning and Inspection .
Fig 3: Removing/Installing 5th Gear Retaining Ring
Courtesy of GENERAL MOTORS CORP.
7. Using 2 screwdrivers and a hammer, remove the 5th gear retaining ring.
Fig 4: Pressing Out 5th Gear And The Output Shaft Rear Bearing
Courtesy of GENERAL MOTORS CORP.
8. Using a hydraulic press, remove the 5th gear and the output shaft rear bearing.
Fig 5: Locating Output Shaft Components
Courtesy of GENERAL MOTORS CORP.
9. Remove the following components from the rear of the output shaft:
   • The 5th gear (150)
   • The output shaft rear bearing (193)
   • The 1st gear thrust washer (116)
   • The 1st gear (110)
   • The 1st gear bearing (113)
Fig 6: Identifying 1st Gear Thrust Washer Lock Pin
Courtesy of GENERAL MOTORS CORP.
10. Remove the 1st gear thrust washer lock pin.
Fig 7: View Of 1st Gear Spacer
Courtesy of GENERAL MOTORS CORP.
11. Remove the 1st gear bearing spacer.
Fig 8: Checking 2nd Gear Axial Play
Courtesy of GENERAL MOTORS CORP.
12. Using J 8001-3  or J 26900-12  (1) and J 26900-13  (2), measure the 2nd gear axial play. See Special Tools .

    Specification: 

    • Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in)
    • Maximum Clearance: 0.30 mm (0.0118 in)
    1. Position J 8001-3  or J 26900-12  (1) on the top of the gear teeth. See Special Tools .
    2. Zero the gage.
    3. Lift up on the gear to measure the clearance.
13. If the clearance exceeds the maximum, refer to Gears and Shafts Cleaning and Inspection .
Fig 9: View Of 1st/2nd Synchronizer Hub Retaining Ring
Courtesy of GENERAL MOTORS CORP.
14. Using 2 screwdrivers and a hammer, remove the 1st/2nd synchronizer hub retaining ring.
Fig 10: Removing 1St/2Nd Gear Synchronizer Hub Using J 45869 & J 22912-01
Courtesy of GENERAL MOTORS CORP.
NOTE: Protect the speed gear teeth when removing the synchronizer hubs to prevent damage to the gear.
15. Install the J 45869  (1) onto the J 22912-B  (2) to protect the gear teeth from chipping. See Special Tools .
16. Install the J 22912-B  (2) with the J 45869  (1) under 2nd gear. See Special Tools .
17. Using a hydraulic press, remove the 1st/2nd gear synchronizer hub.
Fig 11: View Of 1st/2nd Synchronizer Hub Assembly, 2nd Gear & Bearing
Courtesy of GENERAL MOTORS CORP.
18. Remove the following components from the rear of the output shaft:
    • The 1st/2nd gear synchronizer hub assembly (215)
    • The 2nd gear (120)
    • The 2nd gear bearing (123)
Fig 12: Measuring 3rd Gear Axial Play
Courtesy of GENERAL MOTORS CORP.
19. Using J 8001-3  or J 26900-12  (1) and J 26900-13  (2), measure the 3rd gear axial play. See Special Tools .

    Specification: 

    • Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in)
    • Maximum Clearance: 0.30 mm (0.0118 in)
    1. Position J 8001-3  or J 26900-12  (1) on the top of the gear teeth. See Special Tools .
    2. Zero the gage.
    3. Lift up on the gear to measure the clearance.
20. If the clearance exceeds the maximum, refer to Gears and Shafts Cleaning and Inspection .
Fig 13: Locating 3rd/4th Gear Synchronizer Hub Retaining Ring
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The 3rd/4th gear synchronizer hub cannot be used again if removed. A new hub is required for assembly.
21. Remove the 3rd/4th gear synchronizer hub retaining ring.
Fig 14: Removing The 3Rd/4Th Gear Synchronizer Hub Using J 22912-01 & J 45869
Courtesy of GENERAL MOTORS CORP.
NOTE: Protect the speed gear teeth when removing the synchronizer hubs to prevent damage to the gear.
22. Install the J 22912-B  (2) with the J 45869  (1) under the 3rd gear. See Special Tools .
23. Using a hydraulic press, remove the 3rd/4th gear synchronizer hub.
Fig 15: Identifying Output Shaft Components
Courtesy of GENERAL MOTORS CORP.
24. Remove the following components from the front of the output shaft:
    • The 3rd/4th gear synchronizer hub assembly (235)
    • The 3rd gear (130)
    • The 3rd gear bearing (133)