Transmission Assemble

Tools Required

• J 39924-2  5th Gear Drag Seal Installer. See Special Tools .
• J 45866  Input Shaft Seal Installer. See Special Tools .
• J 45867  4WD Output Shaft Seal Installer. See Special Tools .
• J 45868  RWD Output Shaft Seal Installer. See Special Tools .

Fig 1: Installing/Removing Reverse Shift Fork Bracket And Bolts
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Lubricate all bearings with transmission fluid during assembly.
• The following steps apply to both the 4WD and the RWD transmission, except where noted.
1. Install 2 bolts, with nuts, in the lower holes of the intermediate case. The bolts will be used to hold the intermediate case in a vise during assembly.
NOTE: Refer to Machined Surface Damage Notice .
2. Mount the intermediate case in a vise on the previously installed bolts.
NOTE: Refer to Fastener Notice .
3. Install the reverse shift fork bracket with bolts.

   Tighten:  Tighten the bracket bolts to 18 N.m (13 lb ft).

Fig 2: Locating Reverse Gear Shift Shaft
Courtesy of GENERAL MOTORS CORP.
4. Install the reverse gear shift shaft.
5. Turn the shift shaft to align the interlock hole facing up.
6. Using a magnet, install the reverse shift shaft interlock.
Fig 3: View Of Reverse Shift Fork Retaining Ring & Lever
Courtesy of GENERAL MOTORS CORP.
7. Install the reverse shift fork on the reverse shift lever.
8. Install the reverse shift fork retaining ring.
Fig 4: Locating Detent Spring & Ball
Courtesy of GENERAL MOTORS CORP.
9. Install the reverse shift lever on the reverse shift shaft.
   1. Install the detent spring in the lever.
   2. Install the detent ball. Push the ball in while sliding the lever on the shaft.
   3. Slide the lever on the shaft until the detent ball is located in the detent on the shaft.
Fig 5: Identifying Detent Ball In The Reverse Shift Lever
Courtesy of GENERAL MOTORS CORP.
10. Install the detent ball in the reverse shift lever for the 5th shift shaft.
Fig 6: View Of 5th Shift Shaft & Detent Ball
Courtesy of GENERAL MOTORS CORP.
11. Install the 5th shift shaft into the intermediate case.
12. Push down on the detent ball in the reverse shift lever and install the 5th shift shaft.
13. Align the 5th shift shaft with the detents facing toward the detent ball hole at the side of the case.
14. Using a magnet, install the 1st/2nd shift shaft and 5th shift shaft interlock pin.
Fig 7: Locating 1st/2nd Shift Shaft
Courtesy of GENERAL MOTORS CORP.
15. Install the small interlock pin in the 1st/2nd shift shaft.
16. Install the 1st/2nd shift shaft. Ensure to align the interlock pin with the interlock in the 5th shift shaft and the detents toward the detent ball hole in the side of the case.
17. Using a magnet, install the 1st/2nd shift shaft and 3rd/4th shift shaft interlock pin.
Fig 8: Identifying 3rd/4th Shift Shaft
Courtesy of GENERAL MOTORS CORP.
18. Install the 3rd/4th shift shaft. Align the detents on the shaft toward the detent ball holes at the top of the case.
Fig 9: View Of Shift Shaft Detent Springs And Balls
Courtesy of GENERAL MOTORS CORP.
19. Install the 5th shift shaft detent spring and ball. The reverse gear shift shaft does not have a detent spring and ball in the plug opening.
20. Install the 3rd/4th shift shaft detent spring and ball.
21. Install the 1st/2nd shift shaft detent spring and ball.
Fig 10: Locating Shift Shaft Detent Plugs
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The shift detent plugs must not be used again. Always install new plugs.
22. Install the 4 new shift detent plugs for the balls and springs.

    Tighten:  Tighten the shift detent plugs to 19 N.m (14 lb ft).

Fig 11: Identifying Shift Shaft Retaining Rings
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Always use new retaining rings.
• Do not install the retaining ring for the reverse shift shaft at this time.
23. Install the 1st/2nd shift shaft retaining ring.
24. Install the 3rd/4th shift shaft retaining ring.
25. Install the 5th shift shaft retaining ring.
26. Move the shift shafts in the NEUTRAL position.
Fig 12: View Of Retaining Ring Groove On The Reverse Shift Shaft
Courtesy of GENERAL MOTORS CORP.
27. Shift the reverse shift shaft forward.
28. Move the reverse shift lever forward past the retaining ring groove on the reverse shift shaft. This allows the output shaft to clear the reverse shift fork during installation.
Fig 13: Locating 3rd/4th Shift Fork And 1st/2nd Shift Fork
Courtesy of GENERAL MOTORS CORP.
29. Position the 3rd/4th shift fork and the 1st/2nd shift fork on the synchronizer sleeves. To aid during assembly, hold the shift forks in place with rubber bands.
Fig 14: Identifying 1st/2nd Shift Fork & 3rd/4th Shift Fork On Output Shaft Assembly
Courtesy of GENERAL MOTORS CORP.
30. Install the output shaft assembly.
    • Hold the 1st/2nd shift fork (210) and the 3rd/4th shift fork (230) in position to the output shaft.
    • While installing the output shaft, slide the 1st/2nd shift fork (210) and the 3rd/4th shift fork (230) on the shift shafts.
    • The 1st/2nd shift fork (210) goes on the top 2 shift shafts.
    • The 3rd/4th shift fork (230) goes on the top shaft.
    • Wiggle the output shaft assembly to install the output shaft rear bearing in the intermediate case.
Fig 15: View Of Output Shaft Rear Bearing Outer Retaining Ring
Courtesy of GENERAL MOTORS CORP.
31. Install the output shaft rear bearing outer retaining ring.
Fig 16: Locating Retaining Ring On Reverse Shift Lever
Courtesy of GENERAL MOTORS CORP.
32. Move the reverse shift lever and the shift shaft to the NEUTRAL position.
33. Install a new retaining ring for the reverse shift lever on the reverse shift shaft.
Fig 17: Identifying Shift Fork Bolts
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The shift fork bolts must not be used again. Always install new shift fork bolts.
34. Install the 1st/2nd shift fork bolt.
35. Install the 3rd/4th shift fork bolt.

    Tighten:  Tighten the shift fork bolts to 20 N.m (14 lb ft).

Fig 18: View Of Input Shaft Assembly
Courtesy of GENERAL MOTORS CORP.
36. Install the input shaft assembly, with the output shaft front support bearing and the 4th gear blocking ring, to the output shaft. Ensure to align the tabs on the blocking ring to the notches in the synchronizer hub.
Fig 19: Locating Reverse Gear Idler Shaft And Reverse Idler Gear
Courtesy of GENERAL MOTORS CORP.
37. Install the reverse gear idler shaft and reverse idler gear.
    • Ensure the reverse shift fork is in position on the reverse gear.
    • The slot on the reverse gear idler shaft aligns facing upward.
Fig 20: View Of Countershaft & Rear Bearing
Courtesy of GENERAL MOTORS CORP.
38. Install the countershaft in position.
39. Install the countershaft rear bearing. Hold the countershaft in the correct position against the output shaft gears. The bearing will slide in the case.
Fig 21: Identifying Rear Bearing Retainer & Retaining Bolts
Courtesy of GENERAL MOTORS CORP.
40. Install the rear bearing retainer. The retainer installs in the slot on the reverse gear idler shaft.
IMPORTANT: New bolts are not reusable. New bolts must be used when the transmission is re-assembled.
41. Install NEW rear bearing retainer bolts.

    Tighten:  Tighten the retainer bolts to 25 N.m (18 lb ft).

Fig 22: Locating 5th Gear Thrust Washer
Courtesy of GENERAL MOTORS CORP.
42. Install the thrust washer lock pin.
43. Install the 5th gear thrust washer. The tapered edge side of the thrust washer goes toward the countershaft bearing.
Fig 23: View Of 5th/Reverse Synchronizer Assembly & 5th Countershaft Gear Bearing
Courtesy of GENERAL MOTORS CORP.
44. Install the 5th countershaft gear bearing and 5th/reverse synchronizer assembly onto the countershaft.
Fig 24: Removing/Installing 5th Shift Fork Roll Pin
Courtesy of GENERAL MOTORS CORP.
45. Using a hammer and a punch, install a new 5th shift fork roll pin.
Fig 25: Placing 5th Synchronizer Gear In Position
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: When installing the 5th synchronizer gear, ensure to align with the holes for the reverse internal blocking ring tabs. Do not rotate the blocking rings to align with the gear. Rotating the blocking rings would move the rings from the lock position. If the rings become unlocked, the 5th/reverse synchronizer would have to be removed and assembled again.
46. Place the 5th synchronizer gear on the countershaft in the following position:
    • The holes in the gear align with the tabs on the reverse internal blocking ring.
    • The machined side of the hub goes forward, the cut point teeth side forward.
Fig 26: View Of 5th Synchronizer Gear
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Support the front of the countershaft on a press plate. Ensure that the tabs on the blocking ring align in the gear holes. Do not rotate the blocking rings for aligning.
47. Using a hydraulic press and J 39924-2  or equivalent, install the 5th synchronizer gear. See Special Tools .
48. Inspect the 5th/reverse synchronizer assembly for proper installation. The blocking rings should move freely back and forth. If the blocking rings do not move, the rings came out of the lock position. Disassembly is required. Assemble again properly.
Fig 27: Measuring Axial Clearance On 5th Synchronizer Gear
Courtesy of GENERAL MOTORS CORP.
49. Using a feeler gage between the 5th gear and the thrust washer, measure the axial clearance.

    Specification: 

    • Standard Clearance: 0.10-0.35 mm (0.0039-0.0138 in)
    • Maximum Clearance: 0.40 mm (0.0157 in)

50. If the clearance exceeds the maximum, ensure the 5th synchronizer gear is installed completely.
51. If the clearance exceeds the maximum, inspect the 5th countershaft gear, the countershaft, or the thrust washer for wear.
52. If clearance is lower than the standard clearance, inspect the 5th countershaft gear, the countershaft, or the 5th synchronizer gear for burrs.
53. Repair or replace the damaged or worn component.
Fig 28: Identifying 5th Synchronizer Gear Retaining Ring
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The retaining ring is a select fit. Always install a NEW retaining ring.
54. Select the maximum thickness retaining ring for the 5th gear, that will fit. Refer to Fifth Gear Retaining Ring Specifications .
55. Install the 5th synchronizer gear retaining ring.
Fig 29: View Of Transmission Magnet
Courtesy of GENERAL MOTORS CORP.
56. Install the magnet.
Fig 30: Locating Oil Baffle Bolts
Courtesy of GENERAL MOTORS CORP.
57. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the threads of the oil baffle bolts.
58. Install the oil baffle.
59. Install the oil baffle bolts.

    Tighten: 

    • Tighten the oil baffle bolts to the intermediate case to 20 N.m (14 lb ft).
    • Tighten the oil baffle bolts to the shift shaft to 13 N.m (10 lb ft).

Fig 31: Sealant Application Areas On Intermediate Case
Courtesy of GENERAL MOTORS CORP.
60. Apply a 3 mm (1/8 in) bead of sealant GM P/N 89020326 (Canadian P/N 89021188) to the front of the intermediate case.
Fig 32: View Of Transmission Case
Courtesy of GENERAL MOTORS CORP.
61. Support the intermediate case on wooden blocks, with the output shaft over the edge of a workbench, to allow installation of the transmission case.
IMPORTANT: The 4th blocking ring may have moved out of position. The 4th blocking ring tabs should be seated in the notches of the 3rd/4th synchronizer hub.
62. Install the transmission case to the intermediate case.
    • Ensure the 4th blocking ring is seated properly.
    • Ensure the location pins are installed.
    • Slide the transmission case over the shift rails.
    • Use a soft-face hammer to install the transmission case completely to the intermediate case.
    • Do not let the sealer air dry.
Fig 33: Locating Outer Retaining Rings On Input Shaft Bearing & Countershaft Front Bearing
Courtesy of GENERAL MOTORS CORP.
63. Install the countershaft front bearing outer retaining ring. It may be necessary to lift up the countershaft in order to install the retaining ring.
64. Install the input shaft bearing outer retaining ring. If the retaining ring will not seat flush to the case, the 4th blocking ring was not in the correct position.
Fig 34: View Of Input Shaft Seal
Courtesy of GENERAL MOTORS CORP.
65. Using J 45866  , install a new input shaft seal in the input shaft bearing retainer. See Special Tools .
    • The spring side of the seal goes toward the tool.
    • Ensure the seal is installed square.
    • The tool will install the seal to the correct depth.
Fig 35: Sealant Area On Input Shaft Bearing Retainer
Courtesy of GENERAL MOTORS CORP.
66. Apply a 3 mm (1/8 in) bead of sealant GM P/N 89020326 (Canadian P/N 89021188) to the input shaft bearing retainer.
Fig 36: Locating Input Shaft Bearing Retainer Bolts
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Ensure the seal is not caught on the input shaft.
67. Install the input shaft bearing retainer.
IMPORTANT: The input shaft bearing retainer bolts must not be used again. Always install new retainer bolts.
68. Install the bearing retainer bolts.

    Tighten:  Tighten the bearing retainer bolts to 17 N.m (12 lb ft).

Fig 37: Identifying Shift Control Shaft
Courtesy of GENERAL MOTORS CORP.
69. Install the shift control shaft in the shift shaft gates.
Fig 38: Application Areas On Rear Of Intermediate Case
Courtesy of GENERAL MOTORS CORP.
70. Apply a 3 mm (1/8 in) bead of sealant GM P/N 89020326 (Canadian P/N 89021188) to the rear of the intermediate case.
Fig 39: Locating Shift Control Socket At Extension Housing Shift Lever Cavity
Courtesy of GENERAL MOTORS CORP.
71. Install the extension housing to the intermediate case.
    • Slide the case over the shift control shaft.
    • Install the shift control socket on the shift control shaft.
    • Ensure the extension housing is installed completely to the intermediate case.
    • Use a soft-face hammer to tap the extension housing in place.
Fig 40: Identifying Extension Housing Retaining Bolts And Studs
Courtesy of GENERAL MOTORS CORP.
72. Install the extension housing retaining bolts and studs, with the brackets, to the proper location as marked during disassembly.

    Tighten:  Tighten the extension housing bolt and studs to 37 N.m (27 lb ft).

Fig 41: View Of Shift Control Lever Socket Bolt
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Do not use the shift control lever socket bolt again. Always install a new lever socket bolt.
73. Install the control lever bolt.

    Tighten:  Tighten the control lever bolt to 33 N.m (24 lb ft).

Fig 42: Locating Shift Control Housing & Gasket
Courtesy of GENERAL MOTORS CORP.
74. Install the shift control housing with a new gasket.
75. Install the shift control housing bolts.

    Tighten:  Tighten the housing bolts to 20 N.m (14 lb ft).

Fig 43: Identifying Clutch Housing Bolts
Courtesy of GENERAL MOTORS CORP.
76. Using a soft-face hammer to assist, install the clutch housing to the transmission case.
IMPORTANT: Two of the clutch housing bolts require sealant. If sealant is not used, leakage will occur. Always use new bolts.
77. Install the 2 new bolts in the clutch housing location, as shown.
78. Install the remaining clutch housing bolts.

    Tighten:  Tighten the clutch housing bolts to 36 N.m (27 lb ft).

Fig 44: View Of Vehicle Speed Sensor (VSS) With O-Ring Seal - RWD
Courtesy of GENERAL MOTORS CORP.
79. If RWD transmission, install the vehicle speed sensor (VSS) with O-ring seal.

    Tighten:  Tighten the VSS to 17 N.m (12 lb ft).

Fig 45: Locating Output Shaft Seal - RWD
Courtesy of GENERAL MOTORS CORP.
80. If RWD transmission, using the J 45868  , install a new output shaft seal. See Special Tools .
Fig 46: Identifying Output Shaft Seal - 4WD
Courtesy of GENERAL MOTORS CORP.
81. If 4WD transmission, using the J 45867  , install a new output shaft seal. See Special Tools .
Fig 47: View Of Drain Plug
Courtesy of GENERAL MOTORS CORP.
82. Install the drain plug with a new gasket.

    Tighten:  Tighten the drain plug to 37 N.m (27 lb ft).