Transaxle Disassemble

Tools Required

• J 35451  Reverse Light Switch Socket. See Special Tools .
• J 8001  Dial Indicator
• J 26900-13  Magnetic Base
• J 22912-01  Split - Plate Bearing Puller
• J 1859-A  Steering Wheel Puller. See Special Tools .
• J 8433-1  Puller Bar. See Special Tools .

Fig 1: Identifying Clutch Release Fork
Courtesy of GENERAL MOTORS CORP.
1. Remove the clutch release fork and the clutch release bearing.
2. Remove one retaining bolt and remove the vehicle speed sensor (VSS) from the transaxle case.
3. Use the J 35451  to remove the backup switch. See Special Tools .
Fig 2: View of Vehicle Speed Sensor (VSS)
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4. Remove the selecting bellcrank.
5. Remove the lock bolt.
6. Remove the shift and select lever assembly.
7. Remove the engage gears.
8. Remove the fifth gear lock nut.
9. Remove the disengage gears.
10. Remove the case side cover bolts.
11. Remove the case side cover.
Fig 3: View of J 8001 & J 8001
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12. Use the J 8001  with the J 26900-13  to measure the fifth gear thrust clearance. If the clearance is not 0.10-0.65 mm (0.0039-0.0256 in), you must use a selective snap ring on reassembly. Refer to Transaxle Specifications (Selective Snap Ring Table)  or Transaxle Specifications (5th Gear Selective Snp Rng Tbl)  or Transaxle Specifications (Thrust Washer Thickness)  or Transaxle Specifications (Selective Bearing Shim Table)  #1.
13. Remove the fifth gear shift fork lock bolt.
14. Remove the fifth gear shift fork and synchronizer shift sleeve.
15. Remove the fifth gear synchronizer snap ring.
Fig 4: Identifying J 1859-A On Fifth Gear Synchronizer Hub
Courtesy of GENERAL MOTORS CORP.
16. Attach the J 1859-A  to the fifth gear synchronizer hub. See Special Tools .
17. Use the J 1859-A  to remove the fifth gear synchronizer hub (1). See Special Tools .
18. Remove the following components:
    • The synchronizer blocking ring
    • The needle roller bearing
    • The spacer
    • The fifth gear driven gear
19. Unstake the fifth drive gear lock nut.
20. Remove the fifth drive gear lock nut.
Fig 5: View Of J 22912-01 & J 8433-1 Installed To Fifth Drive Gear
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21. Attach the J 22912-01  and the J 8433-1  to the fifth drive gear. See Special Tools .
22. Use the J 22912-01  and the J 8433-1  to remove the fifth drive gear. See Special Tools .
Fig 6: View Of Needle Roller Bearing
Courtesy of GENERAL MOTORS CORP.
23. Remove the following components:
    • The needle roller bearing
    • The spacer
24. Remove the rear bearing retainer.
25. Remove two bearing snap rings.
Fig 7: Identifying Reverse Idler Gear Shaft Lock Bolt
Courtesy of GENERAL MOTORS CORP.
26. Remove the reverse idler gear shaft lock bolt.
27. Use two screwdrivers and a hammer to remove the snap ring from the number 2 shift fork shaft.
28. Remove the following components:
    • Three plugs
    • The lock bolt
    • The lock bolt assembly
Fig 8: Locating Seats, Springs & Balls
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29. Use a magnetic finger to remove the following components:
    • Three seats
    • The springs
    • The balls
Fig 9: Separating Case Halves
Courtesy of GENERAL MOTORS CORP.
30. Remove the case cover by removing 16 bolts.
31. Carefully pry the case halves apart (1).
Fig 10: Locating Reverse Idler Gear
Courtesy of GENERAL MOTORS CORP.
32. Remove the reverse shift arm bracket.
33. Remove the following components:
    • The reverse idler gear (2)
    • The thrust washer
    • The shaft
Fig 11: Removing Snap Rings From Shift Fork Shaft
Courtesy of GENERAL MOTORS CORP.
34. Use two screwdrivers and a hammer to remove three snap rings. Remove 3 set bolts from the shift forks.
35. Remove the following components:
    • The number 2 shift fork shaft
    • The shift head
36. Use a magnetic finger to remove the two balls.
37. Remove the following components:
    • The number 3 shift fork shaft
    • The reverse shift fork
38. Pull out the number 1 shift fork shaft.
39. Remove the following components:
    • The number 1 shift fork shaft
    • The number 2 shift fork shaft
Fig 12: Identifying Output & Input Shafts
Courtesy of GENERAL MOTORS CORP.
40. Remove the following components together:
    • The input shaft (1)
    • The output shaft (2)
41. Remove the differential assembly.
42. Remove the following components:
    • The magnet
    • The oil receiver
Fig 13: View Of Differential Assembly
Courtesy of GENERAL MOTORS CORP.
43. Remove the differential assembly (1).
44. Remove the following components:
    • The magnet
    • The oil receiver
Fig 14: Checking First Gear Thrust Clearance
Courtesy of GENERAL MOTORS CORP.
45. Use a feeler gage to measure the first gear thrust clearance. If the clearance is not 0.10-0.45 mm (0.0039-0.0177 in), replace both of the following components:
    • The first gear
    • The second gear
Fig 15: Measuring Second Gear Thrust Clearance
Courtesy of GENERAL MOTORS CORP.
46. Use a feeler gage to measure the second gear thrust clearance. If clearance is not 0.10-0.50 mm (0.0039-0.0197 in), replace both of the following components:
    • The second gear
    • The third gear
Fig 16: Checking With Feeler Gage Third Gear Thrust Clearance
Courtesy of GENERAL MOTORS CORP.
47. Use a feeler gage to measure the third gear thrust clearance. If the clearance is not 0.10 - 0.40 mm (0.0039 - 0.0157 in), replace both of the following components:
    • The third gear
    • The fourth gear
Fig 17: Measuring Fourth Gear Thrust Clearance With Feeler Gage
Courtesy of GENERAL MOTORS CORP.
48. Use a feeler gage to measure the fourth gear thrust clearance. If the clearance is not 0.10-0.60 mm (0.0039-0.0236 in) replace both of the following components:
    • The fourth gear
    • The fifth gear
Fig 18: Checking Oil Clearance Between Gear & Input Shaft
Courtesy of GENERAL MOTORS CORP.
49. With the needle roller bearing installed, use a J 8001  to measure the oil clearance between the gear and the input shaft. If the clearance is not 0.015-0.070 mm (0.0006-0.0028 in), replace the gear, the needle roller bearing, or the shaft.
Fig 19: Identifying Snap Ring
Courtesy of GENERAL MOTORS CORP.
50. Remove the snap ring from the input shaft.
Fig 20: Locating Fourth Gear
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51. Use a J 22912-01  with a press to remove the radial ball bearing.
52. Remove the following components:
    • The fourth gear
    • The needle roller bearing
    • The synchronizer ring
Fig 21: Using Screwdrivers To Remove Snap Ring
Courtesy of GENERAL MOTORS CORP.
53. Remove the snap ring from the shaft.
Fig 22: View Of Number 2 Hub Sleeve
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54. Use a J 22912-01  with a press to remove the following components:
    • The number 2 hub sleeve
    • The third gear synchronizer ring
    • The needle roller bearing
Fig 23: Identifying J 22912-01
Courtesy of GENERAL MOTORS CORP.
55. Use a J 22912-01  with a press to remove the following components:
    • The radial ball bearing
    • The fourth driver gear
56. Remove the spacer.
Fig 24: View Of Shift Number 1 Hub Sleeve
Courtesy of GENERAL MOTORS CORP.
57. Remove the shift number 1 hub sleeve into the first gear.
58. Use a J 22912-01  with a press to remove the following components:
    • The third driven gear
    • The second gear
59. Remove the following components:
    • The needle roller bearing
    • The spacer
    • The synchronizer ring
Fig 25: View Of Snap Ring Number 1 Hub Sleeve Assembly
Courtesy of GENERAL MOTORS CORP.
60. Remove the snap ring number 1 hub sleeve assembly.
Fig 26: Locating Number 1 Hub
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61. Use a press to remove the following components:
    • The number 1 hub
    • The first gear
    • The synchronizer ring
62. Remove the following components:
    • needle roller bearing
    • The thrust washer
    • The locking ball