Intermediate Shaft Installation

Tools Required

• J 37758  Countershaft Rear Plug Installer. See Special Tools .
• J 8092  Driver Handle
• J 36850  Transjel® Lubricant
• J 8614-01  Countershaft Driven Gear Holder
• J 34826  Hub Nut Socket - 36 mm. See Special Tools .
• J 35552  Differential Side Bearing Cup Installer. See Special Tools .

Fig 1: Identifying J 37758 & J 8092
Courtesy of GENERAL MOTORS CORP.
1. Install the countershaft drive gear outer race (2) into the transaxle case (1) using a J 37758  with a J 8092  and a hydraulic press. See Special Tools .
Fig 2: Locating Countershaft Drive Gear Outer Race Snap Ring
Courtesy of GENERAL MOTORS CORP.
2. Install the countershaft drive gear outer race snap ring (1) onto the countershaft drive gear outer race (2).
3. Install the new crush sleeve onto the countershaft drive gear.
4. Apply J 36850  to the countershaft drive gear and outer bearings.
5. Install the countershaft drive gear into the transaxle case using a J 35552  with a J 8092  and a hydraulic press. See Special Tools .
6. Install the countershaft drive gear inner bearing into the countershaft drive gear outer race.
Fig 3: Intermediate Shaft, Transaxle Case & Countershaft Drive Gear
Courtesy of GENERAL MOTORS CORP.
7. Install the intermediate shaft (2) into the transaxle case (1) and into the countershaft drive gear.
8. Install a J 8614-01  onto the countershaft driven gear stationary during intermediate shaft locknut installation.
NOTE: Refer to Fastener Notice in Cautions and Notices.
9. Install the intermediate shaft locknut onto the intermediate shaft using aJ 34826  . See Special Tools .

   Tighten:  Tighten the intermediate shaft locknut to 177 N.m (131 lb ft).

10. Remove the J 8614-01  from the countershaft driven gear.
11. Stake the intermediate shaft locknut.
Fig 4: Checking Intermediate Shaft For Smooth Rotation
Courtesy of GENERAL MOTORS CORP.
12. Inspect the intermediate shaft (1) for smooth rotation.
13. If the intermediate shaft does not rotate smoothly, remove the countershaft drive gear bearings and inspect for excessive wear or damage.
14. Clean the sealant from the rear case cover mating surfaces on the rear case cover and transaxle case (2).
15. Apply the RTV silicone sealer GM P/N 1052917, or equivalent, to the rear case cover mating surface.
Fig 5: Identifying Rear Case Cover
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Eleven of the 13 rear case cover bolts are 25 mm (0.984 in) in length. The two remaining bolts are 32 mm (1.259 in) in length. Verify that the two longer bolts are installed in their correct position.
16. Install the rear case cover (1) to the transaxle case. Secure the assembly with 13 bolts.

    Tighten:  Tighten the rear case bolts to 10 N.m (89 lb in).