LEMON Manuals: Even more car manuals for everyone
Home >> Pontiac >> 2009 >> Vibe Base, 2.4 0, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Manual Transmission - MVC 5 Speed) >> Repair Instructions - Off Vehicle >> Transmission Assemble

Transmission Assemble

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View of Front Differential Gears, Washers & Front Differential Case
    GM2011801Courtesy of GENERAL MOTORS CORP.
  1. Coat the rotating surface of the front differential side gear with gear oil.
  2. Install the 2 front differential side gear thrust washers to the 2 front differential side gears.
  3. Install the 2 front differential side gears, 2 front differential pinions, and 2 front differential side gear thrust washers to the front differential case.
  4. Install the 2 front differential pinions with the front differential washers while turning the front differential pinion.
    5. Fig 2: View Of No. 1 Front Differential Pinion Shaft & Front Differential Case
    GM2011800Courtesy of GENERAL MOTORS CORP.
  5. Coat the rotating surface of the No. 1 front differential pinion shaft with gear oil.
  6. Install the No. 1 front differential pinion shaft to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.
    7. Fig 3: Installing Front Differential Pinion Shaft Straight Pin To Front Differential Case
    GM2011812Courtesy of GENERAL MOTORS CORP.
  7. Using a pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.
    8. Fig 4: Staking Front Differential Case Hole
    GM2011814Courtesy of GENERAL MOTORS CORP.
  8. Using a chisel and hammer, stake the front differential case hole.
    9. Fig 5: Measuring Front Differential Side Gear Backlash
    GM2011803Courtesy of GENERAL MOTORS CORP.
  9. Hold the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

    Specifications:  Standard backlash - 0.05-0.20 mm (0.002-0.0079 in)

  10. If backlash is out of specification, select another front differential side gear thrust washer and adjust backlash. Refer to General Specifications for Front Differential Side Gear Thrust Washer  .
    11. Fig 6: Heating Front Differential Ring Gear
    GM2011266Courtesy of GENERAL MOTORS CORP.
  11. Clean the surface that contacts the differential case.
  12. Using a heater, heat the front differential ring gear to 90-110°C (194-230°F).
    13. Fig 7: View Of Front Differential Case, Front Differential Ring Gear & Bolts
    GM2011834Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution
  13. After moisture on the ring gear has completely evaporated, align the matchmarks, quickly install the front differential ring gear to the front differential case with the 16 bolts and tighten to 106 N.m (78 lb ft).
    14. Fig 8: Install Speedometer Drive Gear To Front Differential Case
    GM2011836Courtesy of GENERAL MOTORS CORP.
  14. Install the speedometer drive gear to the front differential case.
    15. Fig 9: Installing No. 1 Synchromesh Shifting Keys To Reverse Gear
    GM2011764Courtesy of GENERAL MOTORS CORP.
    NOTE: Assemble the reverse gear and the No. 1 transmission clutch hub in the correct direction.
  15. Coat the reverse gear with gear oil.
  16. Install the 3 No. 1 synchromesh shifting key springs and No. 1 transmission clutch hub to the reverse gear.
  17. Using a screwdriver, install the 3 No. 1 synchromesh shifting keys to the reverse gear.
    18. Fig 10: Installing Output Shaft Front Bearing (Inner Race) To Output Shaft
    GM2011766Courtesy of GENERAL MOTORS CORP.
  18. Using a press (1), install the output shaft front bearing (inner race) to the output shaft.
    19. Fig 11: View Of No. 1 Synchronizer Ring Set
    GM2011767Courtesy of GENERAL MOTORS CORP.
    NOTE: Align the No. 1 synchronizer ring set with the hole of the 1st gear.
  19. Coat the No. 1 synchronizer ring set with gear oil and install it to the 1st gear.
    20. Fig 12: View Of 1St Gear Needle Roller Bearing & Output Shaft
    GM2011768Courtesy of GENERAL MOTORS CORP.
  20. Coat the 1st gear needle roller bearing with gear oil and install it to the output shaft.
    21. Fig 13: Coating 1St Gear With Gear Oil And Install It To Output Shaft
    GM2011770Courtesy of GENERAL MOTORS CORP.
  21. Coat the 1st gear with gear oil and install it to the output shaft.
    22. Fig 14: Aligning No. 1 Synchronizer Ring With No. 1 Synchromesh Shifting Key
    GM2011773Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • Align the No. 1 synchronizer ring with the No. 1 synchromesh shifting key.
    • Make sure that the 1st gear rotates.
  22. Using a press (1), install the No. 1 transmission clutch hub to the output shaft.
    23. Fig 15: Identifying 2Nd Gear Bushing Ball
    GM2011774Courtesy of GENERAL MOTORS CORP.
  23. Coat the gear bushing ball (1) with MP grease, and install it to the output shaft.
    24. Fig 16: Locating 2Nd Gear Bushing
    GM2011776Courtesy of GENERAL MOTORS CORP.

  24. Coat the 2nd gear bushing with gear oil and install it to the output shaft.

    25. Fig 17: View Of 2Nd Gear Bearing Spacer & Output Shaft
    GM2011779Courtesy of GENERAL MOTORS CORP.
  25. Coat the 2nd gear bearing spacer with gear oil and install it to the output shaft.
    26. Fig 18: View Of 2Nd Gear Needle Roller Bearing & Output Shaft
    GM2011535Courtesy of GENERAL MOTORS CORP.
  26. Coat the 2nd gear needle roller bearing with gear oil and install it to the output shaft.
    27. Fig 19: View Of No. 2 Synchronizer Ring Set From No. 1 Transmission Clutch Hub
    GM2011533Courtesy of GENERAL MOTORS CORP.
    NOTE: Align the key groove on the No. 2 synchronizer ring set with the No. 1 synchromesh shifting key.
  27. Coat the No. 2 synchronizer ring set with gear oil and install it to the No. 1 transmission clutch hub.
    28. Fig 20: Coating 2ND Gear With Gear Oil And Install It To Output Shaft
    GM2011782Courtesy of GENERAL MOTORS CORP.
  28. Coat the 2nd gear with gear oil and install it to the output shaft.
    29. Fig 21: Installing 3RD Driven Gear To Output Shaft
    GM2011783Courtesy of GENERAL MOTORS CORP.
  29. Using a press (1), install the 3rd driven gear to the output shaft.
    30. Fig 22: View Of Output Gear Spacer From Output Shaft
    GM2011520Courtesy of GENERAL MOTORS CORP.
  30. Install the output gear spacer to the output shaft.
    31. Fig 23: Installing 4Th Driven Gear To Output Shaft
    GM2011785Courtesy of GENERAL MOTORS CORP.
  31. Using a press (1), install the 4th driven gear to the output shaft.
    32. Fig 24: Installing Output Shaft Front Bearing (Inner Race) To Output Shaft
    GM2011787Courtesy of GENERAL MOTORS CORP.
  32. Using a press (1), install the output shaft front bearing (inner race) to the output shaft.
    33. Fig 25: Installing The Input Shaft Front Bearing (Inner Race)
    GM2011475Courtesy of GENERAL MOTORS CORP.
  33. Using a press (1), install the input shaft front bearing (inner race).
    34. Fig 26: Coating No. 2 Transmission Hub Sleeve With Gear Oil
    GM2011478Courtesy of GENERAL MOTORS CORP.
  34. Coat the No. 2 transmission hub sleeve with gear oil.
    35. NOTE: Install the No. 2 transmission clutch hub sleeve and the No. 2 transmission clutch hub in the correct direction.
  35. Using a screwdriver, install the synchromesh shifting key (1) to the input shaft.
    36. Fig 27: View Of 3Rd Gear Needle Roller Bearing & Input Shaft
    GM2011480Courtesy of GENERAL MOTORS CORP.
  36. Coat the 3rd gear bearing with gear oil and install it to the input shaft.
    37. Fig 28: Coating 3Rd Gear With Gear Oil And Installing It To The Input Shaft
    GM2011483Courtesy of GENERAL MOTORS CORP.
  37. Coat the 3rd gear with gear oil and install it to the input shaft.
    38. Fig 29: Coating No. 3 Synchronizer Ring With Gear Oil And Installing It To 3Rd Gear
    GM2011485Courtesy of GENERAL MOTORS CORP.
  38. Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear.
    39. Fig 30: Installing No. 2 Transmission Clutch Hub To Input Shaft
    GM2011487Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • Align the claw of the clutch hub No. 2 with the notch of the No. 3 synchronizer ring.
    • Make sure that the 3rd gear can rotate.
  39. Using a press, install the No. 2 transmission clutch hub to the input shaft.
    40. Fig 31: Installing Snap Ring Using A Brass Bar And A Hammer
    GM2011489Courtesy of GENERAL MOTORS CORP.
  40. Select a snap ring so that clearance between the No. 2 transmission clutch hub and the No. 2 clutch hub shaft snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring.

    Specifications:  Standard clearance - 0.1 mm (0.0039 in) or less

    Refer to General Specifications for Snap Ring - 1. 

    41. Fig 32: Identifying 4Th Gear Bearing Spacer & No. 2 Transmission Clutch Hub
    GM2011224Courtesy of GENERAL MOTORS CORP.
  41. Coat the 4th gear bearing spacer with gear oil and install it to the input shaft.
    42. Fig 33: View Of No. 4 Synchronizer Ring & No. 2 Transmission Clutch Hub
    GM2011221Courtesy of GENERAL MOTORS CORP.
    NOTE: Align the claw of the No. 2 clutch hub with the notch of the No. 4 synchronizer ring.
  42. Coat the No. 4 synchronizer ring with gear oil and install it to the No. 2 transmission clutch hub.
    43. Fig 34: Identifying 4Th Gear Needle Roller Bearing
    GM2011216Courtesy of GENERAL MOTORS CORP.
  43. Coat the 4th gear needle roller bearing with gear oil and install it to the input shaft.
    44. Fig 35: View Of 4Th Gear With Gear Oil And Input Shaft
    GM2011499Courtesy of GENERAL MOTORS CORP.
  44. Coat the 4th gear with gear oil and install it to the input shaft.
    45. Fig 36: Installing Input Shaft Rear Radial Ball Bearing To Input Shaft Using A Press
    GM2011505Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • Install the bearing with its groove facing rearward.
    • Make sure that the 3rd gear rotates.
  45. Using a press (1), install the input shaft rear radial ball bearing to the input shaft.
    46. Fig 37: Installing Snap Ring Using A Brass Bar And A Hammer
    GM2011507Courtesy of GENERAL MOTORS CORP.
  46. Select a snap ring so that the clearance between the input shaft radial ball rear bearing and the input shaft rear bearing snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring.

    Specifications:  Standard clearance - 0.1 mm (0.004 in) or less

    Refer to General Specifications for Snap Ring - 2  .

    47. Fig 38: Securing Them With Snap Ring
    GM2010934Courtesy of GENERAL MOTORS CORP.
  47. Install the No. 5 synchronizer ring middle, No. 5 synchronizer ring outer, and synchronizer pull ring to the No. 5 synchronizer ring inner. Using a screwdriver, secure them with the snap ring.
    48. Fig 39: Installing No. 3 Synchromesh Shifting Key Spring To No. 3 Transmission Clutch Hub
    GM2010938Courtesy of GENERAL MOTORS CORP.
    NOTE: Align the projection of the shifting key spring with the hole of the No. 3 clutch hub.
  48. Install the No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.
    49. NOTE:
    • Engage the shifting key spring claw to the center of the teeth of the synchronizer ring.
    • Align the projection of the shifting key spring with the hole of the No. 3 clutch hub.
  49. Install the synchronizer ring set and No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.
  50. Coat the new transaxle case oil seal lip with MP grease.
    51. Fig 40: Using A Suitable Driver (1) And A Hammer, Install A Transaxle Case Oil Seal.
    GM2010940Courtesy of GENERAL MOTORS CORP.
  51. Using a suitable driver (1) and a hammer, install a transaxle case oil seal.

    Specification:  Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in)

    52. Fig 41: Installing Front Differential Case Front Tapered Roller Bearing (Outer Race) To Manual Transaxle Case
    GM2010943Courtesy of GENERAL MOTORS CORP.
  52. Install the front differential case front tapered roller bearing (outer race) to the manual transaxle case.
    53. Fig 42: Installing Front Differential Case Front Tapered Roller Bearing (Inner Race) To Front Differential Case Using A Press
    GM2010945Courtesy of GENERAL MOTORS CORP.
  53. Using a press (1), install the front differential case front tapered roller bearing (inner race) to the front differential case.
    54. Fig 43: Installing Front Differential Case Rear Shim
    GM2010947Courtesy of GENERAL MOTORS CORP.
  54. Install the front differential case rear shim.
  55. Install the front differential case rear tapered roller bearing (outer race).
    56. Fig 44: Installing Front Differential Case Rear Tapered Roller Bearing (Inner Race) Using A Press
    GM2010949Courtesy of GENERAL MOTORS CORP.

  56. Using a press (1), install the front differential case rear tapered roller bearing (inner race).

    57. Fig 45: Installing A Transmission Case Oil Seal To Manual Transmission Case Using A Suitable Driver And A Hammer
    GM2010951Courtesy of GENERAL MOTORS CORP.
  57. Using a suitable driver (1) and a hammer, install a transmission case oil seal to the manual transmission case.

    Specification:  Oil seal installation depth - 3.0-4.0 mm (0.1181-0.1575 in)

  58. Coat the transmission case oil seal lip with MP grease.
    59. Fig 46: Installing Output Shaft Rear Bearing (Outer Race) To Manual Transmission Case Using A Suitable Driver And A Hammer
    GM2010954Courtesy of GENERAL MOTORS CORP.
  59. Using a suitable driver (1) and a hammer, install the output shaft rear bearing (outer race) to the manual transmission case.

    Specifications:  Clearance - 3.8-4.4 mm (0.150-0.173 in)

    60. Fig 47: Aligning Projection Of Output Shaft Cover With Transmission Groove
    GM2010958Courtesy of GENERAL MOTORS CORP.
    NOTE: Align the projection of the output shaft cover with the transmission groove.
  60. Coat the output shaft cover with MP grease, and install it to the manual transaxle case.
    61. Fig 48: Installing New Output Shaft Front Bearing (Outer Race) Using A Suitable Driver And A Hammer
    GM2010961Courtesy of GENERAL MOTORS CORP.
  61. Using a suitable driver (1) and a hammer, install the new output shaft front bearing (outer race).
    62. Fig 49: Installing Output Shaft To Manual Transaxle Case
    GM2010963Courtesy of GENERAL MOTORS CORP.
  62. Install the output shaft to the manual transaxle case.
    63. Fig 50: View Of Manual Transmission Case Bolts
    GM2010756Courtesy of GENERAL MOTORS CORP.
  63. Install the transmission case to the manual transaxle case with the 14 bolts (1) and tighten to 29 N.m (21 lb ft).
    64. Fig 51: Installing Bolts To Manual Transaxle Case
    GM2010967Courtesy of GENERAL MOTORS CORP.
  64. Install the 3 bolts (1) to the manual transaxle case and tighten to 29 N.m (21 lb ft).
    65. Fig 52: Installing Output Shaft Rear Bearing Case Shim To Output Shaft
    GM2010969Courtesy of GENERAL MOTORS CORP.
  65. Install the output shaft rear bearing case shim to the output shaft.
    66. Fig 53: Installing Rear Bearing Retainer To Manual Transmission Case With Screws
    GM2010972Courtesy of GENERAL MOTORS CORP.
  66. Install the rear bearing retainer to the manual transmission case with the 7 screws and tighten to 43 N.m (32 lb ft).
    67. Fig 54: Turning Output Shaft In Both Directions To Make Sure That It Starts To Turn Smoothly
    GM2010974Courtesy of GENERAL MOTORS CORP.
  67. Turn the output shaft in both directions to make sure that it starts to turn smoothly.
  68. Using a socket wrench and torque wrench, inspect the preload. Refer to General Specifications for Preload  .
  69. If preload is not as specified, select a proper output shaft rear bearing shim and adjust it.

    The preload of all the output shaft rear bearing shim varies in torque from about 0.04-0.06 N.m (0.35-0.53 lb in). Refer to General Specifications for Output Shaft Rear Shim Thickness. 

  70. Remove the output shaft rear set nut from the output shaft.
    71. Fig 55: Removing Screws And Rear Bearing Retainer From Manual Transmission Case
    GM2010978Courtesy of GENERAL MOTORS CORP.
  71. Remove the 7 screws and rear bearing retainer from the manual transmission case.
    72. Fig 56: Installing Output Shaft Rear Bearing Case Shim To Output Shaft
    GM2010969Courtesy of GENERAL MOTORS CORP.
  72. Remove the output shaft rear bearing shim from the output shaft.
    73. Fig 57: Installing Bolts To Manual Transaxle Case
    GM2010967Courtesy of GENERAL MOTORS CORP.
  73. Remove the 3 bolts (1).
    74. Fig 58: View Of Manual Transmission Case Bolts
    GM2010756Courtesy of GENERAL MOTORS CORP.
  74. Remove the 14 bolts (1) and manual transmission case from the manual transaxle case.
    75. Fig 59: Installing Output Shaft To Manual Transaxle Case
    GM2010963Courtesy of GENERAL MOTORS CORP.
  75. Remove the output shaft assembly from the front manual transaxle case.
    76. Fig 60: View Of Differential Case Assembly
    GM2010830Courtesy of GENERAL MOTORS CORP.
  76. Install the differential case assembly to the manual transaxle case.
    77. Fig 61: View Of Manual Transmission Case Bolts
    GM2010756Courtesy of GENERAL MOTORS CORP.
  77. Install the 14 bolts (1) and manual transmission case to the manual transaxle case, tighten the bolts to 29 N.m (21 lb ft).
    78. Fig 62: Installing Bolts To Manual Transaxle Case
    GM2010967Courtesy of GENERAL MOTORS CORP.
  78. Install the 3 bolts (1) to the manual transaxle case and tighten to 29 N.m (21 lb ft).
  79. Turn the differential case in both directions to make sure that it starts to turn smoothly.
    80. Fig 63: Inspecting Preload Using Torque Wrench
    GM2010994Courtesy of GENERAL MOTORS CORP.
  80. Using J 35405  and a torque wrench, inspect preload. Refer to General Specifications for Preload. 

    If preload is not as specified, select a proper front differential case rear shim and adjust it.

    The preload of all the front differential case rear shims varies in torque from about 0.04-0.06 N.m (0.35-0.53 lb in). Refer to General Specifications for Front Differential Case Rear Shim Thickness. 

    81. Fig 64: Installing Bolts To Manual Transaxle Case
    GM2010967Courtesy of GENERAL MOTORS CORP.
  81. Remove the 3 bolts (1).
    82. Fig 65: View Of Manual Transmission Case Bolts
    GM2010756Courtesy of GENERAL MOTORS CORP.
  82. Remove the 14 bolts (1) and manual transmission case from the manual transaxle case.
    83. Fig 66: View Of Differential Case Assembly
    GM2010830Courtesy of GENERAL MOTORS CORP.
  83. Remove the differential case assembly from the manual transaxle case.
  84. Coat the lip of the new front transaxle case cover oil seal with MP grease.
    85. Fig 67: Installing A New Front Transaxle Case Cover Oil Seal To Manual Transaxle Case Using A Suitable Driver And A Hammer
    GM2011000Courtesy of GENERAL MOTORS CORP.
  85. Using a suitable driver (1) and a hammer, install a new front transaxle case cover oil seal to the manual transaxle case.

    Specifications:  Clearance - 1.0-2.0 mm (0.0394-0.0787 in)

  86. Coat the new input shaft front bearing with gear oil.
    87. Fig 68: Installing Oil Seal To Manual Transaxle Case Using A Suitable Driver And A Hammer
    GM2011002Courtesy of GENERAL MOTORS CORP.
  87. Using a suitable driver (1) and a hammer, install the oil seal to the manual transaxle case.

    Specifications:  Clearance - 4.28-4.60 mm (0.1685-0.1811 in)

    88. Fig 69: Identifying Manual Transaxle Case Receiver Bolts
    GM2011010Courtesy of GENERAL MOTORS CORP.
  88. Install the manual transaxle case receiver to the manual transaxle case with the 3 bolts (1) and tighten to 7.0 N.m (62 lb in).
    89. Fig 70: View Of Differential Case Assembly
    GM2010830Courtesy of GENERAL MOTORS CORP.
  89. Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the manual transaxle case.
    90. Fig 71: Lifting Differential Case Assembly With Output Shaft Assembly Leaned
    GM2011015Courtesy of GENERAL MOTORS CORP.
  90. Apply gear oil to each sliding part of the output shaft assembly.
  91. Lift the differential case assembly with the output shaft assembly leaned, and install it to the manual transaxle case.
    92. Fig 72: Tilting Output Shaft
    GM2011019Courtesy of GENERAL MOTORS CORP.
  92. Apply gear oil to each sliding part of the input shaft assembly.
  93. Install the input shaft assembly to the manual transaxle case while tilting the output shaft assembly.
    94. Fig 73: Identifying No. 2 Gear Shift Fork
    GM2010816Courtesy of GENERAL MOTORS CORP.
  94. Coat the No. 2 gear shift fork (1) with gear oil, and install it to the input shaft assembly.
    95. Fig 74: Installing Shift Fork Shaft Snap Rings To Gear Shift Fork Shaft Using A Brass Bar And Hammer
    GM2011032Courtesy of GENERAL MOTORS CORP.
  95. Install the No. 3 gear shift fork to the No. 3 gear shift fork shaft.
  96. Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft.
    97. Fig 75: Identifying No. 3 Gear Shift Fork Shaft
    GM2010807Courtesy of GENERAL MOTORS CORP.
  97. Apply gear oil to each sliding part of the No. 3 gear shift fork shaft (1), and install it to the manual transaxle case.
    98. Fig 76: Locating No. 1 Gear Shift Fork
    GM2010804Courtesy of GENERAL MOTORS CORP.
  98. Apply gear oil to each sliding part of the No. 1 gear shift fork (1), and install it to the output shaft assembly.
    99. Fig 77: Identifying Manual Transaxle Case No. 2 Gear Shift Fork Shaft And No. 1 Gear Shift Head
    GM2010799Courtesy of GENERAL MOTORS CORP.
  99. Install the No. 1 gear shift head to the No. 2 gear shift fork shaft.
  100. Apply gear oil to each sliding part of the No. 2 gear shift fork shaft (2), and install it to the manual transaxle case.
    101. Fig 78: Installing Shift Fork Set Bolt And Shift Head Set Bolt To No. 1 Gear Shift Head
    GM2011034Courtesy of GENERAL MOTORS CORP.
  101. Install the shift fork set bolt (1) and shift head set bolt to the No. 1 gear shift head and tighten to 24 N.m (18 lb ft).
    102. Fig 79: Identifying Magnetic Pick-Up Tool, Reverse Shift Fork Roller & Reverse Shift Fork
    GM2011036Courtesy of GENERAL MOTORS CORP.
  102. Using a magnetic pick-up tool, install the reverse shift fork roller to the reverse shift fork.
    103. Fig 80: Installing Shift Fork Shaft Snap Ring To No. 1 Shift Fork Shaft Using A Brass Bar And Hammer
    GM2011041Courtesy of GENERAL MOTORS CORP.
  103. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 shift fork shaft.
    104. Fig 81: View Of No. 1 Gear Shift Fork Shaft & No. 3 Gear Shift Fork Shaft
    GM2010782Courtesy of GENERAL MOTORS CORP.
  104. Install the No. 1 gear shift fork shaft (1) to the manual transaxle case.
    105. Fig 82: Identifying No. 1 Gear Shift Fork Shift Fork Set Bolt
    GM2011050Courtesy of GENERAL MOTORS CORP.
  105. Install the shift fork set bolt (1) to the No. 1 gear shift fork and tighten to 24 N.m (18 lb ft).
    106. Fig 83: Locating Manual Transaxle Case Reverse Shift Arm Bracket Assembly Bolts
    GM2011053Courtesy of GENERAL MOTORS CORP.
  106. Install the reverse shift arm bracket assembly to the manual transaxle case with the 2 bolts (1) and tighten to 17 N.m (13 lb ft).
    107. Fig 84: Identifying Magnetic Pick-Up Tool, Reverse Shift Fork Roller & Reverse Shift Fork
    GM2011036Courtesy of GENERAL MOTORS CORP.
  107. Using a magnetic pick-up tool, install the reverse shift fork roller to the reverse shift fork.
    108. Fig 85: Installing Shift Fork Shaft Snap Ring To No. 1 Shift Fork Shaft Using A Brass Bar And Hammer
    GM2011041Courtesy of GENERAL MOTORS CORP.
  108. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 shift fork shaft.
    109. Fig 86: View Of No. 1 Gear Shift Fork Shaft & No. 3 Gear Shift Fork Shaft
    GM2010782Courtesy of GENERAL MOTORS CORP.
  109. Install the No. 1 gear shift fork shaft (1) to the manual transaxle case.
    110. Fig 87: Identifying No. 1 Gear Shift Fork Shift Fork Set Bolt
    GM2011050Courtesy of GENERAL MOTORS CORP.
  110. Install the shift fork set bolt (1) to the No. 1 gear shift fork and tighten to 24 N.m (18 lb ft).
    111. Fig 88: Locating Manual Transaxle Case Reverse Shift Arm Bracket Assembly Bolts
    GM2011053Courtesy of GENERAL MOTORS CORP.
  111. Install the reverse shift arm bracket assembly to the manual transaxle case with the 2 bolts (1) and tighten to 17 N.m (13 lb ft).
    112. Fig 89: Identifying Reverse Gear, Reverse Idler Thrust Washer & Reverse Idler Gear Shaft
    GM2011054Courtesy of GENERAL MOTORS CORP.
  112. Coat the reverse idler gear and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.
    113. Fig 90: Aligning Mark Of Reverse Idler Gear Shaft With Hole Of Bolt
    GM2011057Courtesy of GENERAL MOTORS CORP.
    NOTE: Align the mark of the reverse idler gear shaft with the hole of the bolt (1).
  113. Install the reverse idler gear to the manual transaxle case.
    114. Fig 91: Cleaning Transmission Magnet And Installing It To Manual Transaxle Case
    GM2011059Courtesy of GENERAL MOTORS CORP.
  114. Clean the transmission magnet and install it to the manual transaxle case.
    115. Fig 92: Locating Manual Transmission Case No. 1 Oil Receiver Pipe Bolt
    GM2011060Courtesy of GENERAL MOTORS CORP.
  115. Install the No. 1 oil receiver pipe to the manual transmission case with the bolt (1) and tighten to 17 N.m (13 lb ft).
    116. Fig 93: View Of Manual Transmission Case No. 2 Oil Receiver Pipe Bolt
    GM2011062Courtesy of GENERAL MOTORS CORP.
  116. Install the No. 2 oil receiver pipe to the manual transmission case with the bolt (1).
    117. Fig 94: Identifying Transmission Oil Baffle And Reverse Restrict Pin Assembly Bolt
    GM2011066Courtesy of GENERAL MOTORS CORP.
  117. Install the transmission oil baffle and reverse restrict pin with the bolt (1) and tighten to 17 N.m (13 lb ft).
    118. Fig 95: Installing Slotted Pin To Reverse Restrict Pin Assembly Using A Pin Punch
    GM2011069Courtesy of GENERAL MOTORS CORP.
  118. Using a pin punch, install the slotted pin to the reverse restrict pin assembly.

    Specifications:  Clearance A - 12.5-13.5 mm (0.492-0.531 in)

    119. Fig 96: Identifying Reverse Restrict Pin Plug
    GM2011073Courtesy of GENERAL MOTORS CORP.
  119. Coat the reverse restrict pin plug with adhesive. Using a hexagon wrench (6 mm), install the plug (1) in the manual transmission case and tighten to 13 N.m (9.6 lb ft).
    120. Fig 97: Applying A Bead Of Sealant To Manual Transmission
    GM2011076Courtesy of GENERAL MOTORS CORP.
  120. Apply a bead of sealant to the manual transmission case as shown.
    121. Fig 98: View Of Manual Transmission Case Bolts
    GM2010756Courtesy of GENERAL MOTORS CORP.
  121. Install the manual transmission case to the manual transaxle case with the 14 bolts (1) and tighten to 29 N.m (21 lb ft)
    122. Fig 99: Installing Bolts To Manual Transaxle Case
    GM2010967Courtesy of GENERAL MOTORS CORP.
  122. Coat the 3 bolts with sealant.
  123. Install the 3 bolts (1) to the manual transaxle case.
    124. Fig 100: Identifying Reverse Idler Gear Shaft Bolt And Gasket
    GM2011090Courtesy of GENERAL MOTORS CORP.
  124. Coat the bolt with adhesive. Install a new gasket to the manual transmission case with the bolt (1) and tighten to 30 N.m (22 lb ft)
    125. Fig 101: Using A Brass Bar And Hammer, Install The Shift Fork Shaft Snap Ring To The No. 1 Gear Shift Fork Shaft.
    GM2011093Courtesy of GENERAL MOTORS CORP.
  125. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 gear shift fork shaft.
    126. Fig 102: Installing Shift Fork Shaft Snap Ring To No. 2 Gear Shift Fork Shaft Using A Brass Bar And Hammer
    GM2011097Courtesy of GENERAL MOTORS CORP.
  126. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 2 gear shift fork shaft.
    127. Fig 103: Installing Input Shaft Rear Bearing Shaft Snap Ring Using A Snap Ring Expander
    GM2011099Courtesy of GENERAL MOTORS CORP.
  127. Using a snap ring expander, install the input shaft rear bearing shaft snap ring.
    128. Fig 104: View Of Rear Bearing Shim Output Shaft
    GM2011101Courtesy of GENERAL MOTORS CORP.
  128. Install the output shaft rear bearing shim to the output shaft.
    129. Fig 105: Installing Rear Bearing Retainer To Manual Transmission Case With Screws
    GM2011102Courtesy of GENERAL MOTORS CORP.
  129. Coat the 7 screws with sealant.
  130. Install the rear bearing retainer to the manual transmission case with the 7 screws and tighten to 43 N.m (322 lb ft)
    131. Fig 106: Installing 5Th Driven Gear To Output Shaft
    GM2011105Courtesy of GENERAL MOTORS CORP.
  131. Using DT-49187, install the 5th driven gear to the output shaft.
    132. Fig 107: Identifying 5Th Gear Needle Roller Bearing & Input Shaft Install The 5Th Driven Gear To The Output Shaft
    GM2011112Courtesy of GENERAL MOTORS CORP.
  132. Coat the 5th gear needle roller bearing with gear oil and install it to the input shaft.
    133. Fig 108: View Of 5Th Gear From Input Shaft
    GM2011115Courtesy of GENERAL MOTORS CORP.
  133. Coat the 5th gear with gear oil and install it to the input shaft.
    134. NOTE: Align the projection of the synchronizer ring with the hole of the 5th gear.
  134. Install the No. 3 transmission clutch hub to the input shaft.
    135. Fig 109: Installing No. 3 Transmission Hub Sleeve And No. 3 Gear Shift Fork To No. 3 Transmission Clutch Hub
    GM2011120Courtesy of GENERAL MOTORS CORP.
  135. Install the No. 3 transmission hub sleeve and No. 3 gear shift fork to the No. 3 transmission clutch hub.
    136. Fig 110: Coating Shift Fork Set Bolt With Sealant And Then Installing It To No. 3 Gear Shift Fork
    GM2011122Courtesy of GENERAL MOTORS CORP.
  136. Coat the shift fork set bolt (1) with sealant and then install it to the No. 3 gear shift fork and tighten to 24 N.m (18 lb ft)
    137. Fig 111: Installing Shaft Snap Ring Using A Brass Bar And A Hammer
    GM2011125Courtesy of GENERAL MOTORS CORP.
  137. Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, install the shaft snap ring. Refer to General Specifications for Snap Ring Clearance Thickness Chart. 

    Specifications:  Clearance - 0.1 mm (0.004 in) or less

    138. Fig 112: Engaging 1St And 2Nd Gears Simultaneously
    GM2011129Courtesy of GENERAL MOTORS CORP.
  138. Engage the 1st and 2nd gears simultaneously.
    139. Fig 113: Installing A New Manual Transmission Output Shaft Rear Set Nut
    GM2011132Courtesy of GENERAL MOTORS CORP.
  139. Install a new manual transmission output shaft rear set nut and tighten to 123 N.m (90 lb ft).
    140. Fig 114: Staking Manual Transmission Output Shaft Rear Set Nut Using A Chisel And A Hammer
    GM2011133Courtesy of GENERAL MOTORS CORP.
  140. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
  141. Disengage the gears.
    142. Fig 115: Applying Sealant To Manual Transmission Case Cover Sub-Assembly
    GM2011136Courtesy of GENERAL MOTORS CORP.
  142. Apply sealant to the manual transmission case cover sub-assembly as shown in the installation.
    143. Fig 116: View Of Manual Transmission Case Cover Bolts
    GM2010699Courtesy of GENERAL MOTORS CORP.
  143. Install the manual transmission case cover subassembly to the manual transaxle case with the 10 bolts (1).
    144. Fig 117: Identifying Drain Plug
    GM2011139Courtesy of GENERAL MOTORS CORP.
  144. Install the drain plug (1) to the manual transmission case with a new gasket and tighten to 49 N.m (36 lb ft).
    145. Fig 118: Installing Manual Transmission Filler Plug
    GM2011141Courtesy of GENERAL MOTORS CORP.
  145. Install the manual transmission filler plug (1) to the transaxle case with a new gasket and tighten to 49 N.m (36 lb ft).
    146. Fig 119: View Of Shift And Select Lever Shaft Assembly
    GM2011144Courtesy of GENERAL MOTORS CORP.
  146. Coat the shift and select lever shaft assembly with gear oil, and install it to the manual transmission case.
    147. Fig 120: Installing Back-Up Light Switch Assembly
    GM2011147Courtesy of GENERAL MOTORS CORP.
  147. Install the back-up light switch assembly (1) to the manual transmission case with a new gasket and tighten to 40 N.m (30 lb ft).
    148. Fig 121: View Of Manual Transmission Breather Plug
    GM2011149Courtesy of GENERAL MOTORS CORP.
  148. Install the manual transmission breather plug (1) to the manual transmission case.
    149. Fig 122: Locating Manual Transmission Case Shift Gate Pin
    GM2011150Courtesy of GENERAL MOTORS CORP.
  149. Install the shift gate pin (1) to the manual transmission case and tighten to 29 N.m (21 lb ft).
    150. Fig 123: Identifying Manual Transmission Case No. 1 Lock Ball Assembly
    GM2011153Courtesy of GENERAL MOTORS CORP.
  150. Install the No. 1 lock ball assembly to the manual transmission case with the pin and tighten to 29 N.m (21 lb ft)..
    151. Fig 124: Identifying Clutch Tube Bracket Bolt
    GM2011166Courtesy of GENERAL MOTORS CORP.
  151. Install the No. 2 clutch tube bracket (1) with the bolt and tighten to 15 N.m (11 lb ft).
    152. Fig 125: Identifying Manual Transmission Case, Control Shaft Cover & Bolts
    GM2011169Courtesy of GENERAL MOTORS CORP.
  152. Coat the 4 bolts (1) with sealant. Install a new gasket and the control shaft cover with the bolts and tighten to 20 N.m (15 lb ft).
    153. Fig 126: Identifying Spring Washer Nut
    GM2011180Courtesy of GENERAL MOTORS CORP.
  153. Install the control shift lever with the shift outer lever lock pin (1) to the shift and select lever shaft.
  154. Install the spring washer with the nut and tighten to 12 N.m (9 lb ft).
    155. Fig 127: Locating Manual Transmission Case Bolts
    GM2011184Courtesy of GENERAL MOTORS CORP.
  155. Coat the 2 bolts (1, 2) with sealant. Install the selecting bellcrank assembly to the manual transmission case with the bolts and tighten to 20 N.m (15 lb ft).
  156. Install a new O-ring and the speedometer driven hole cover sub-assembly to the transmission case with the bolt and tighten to 5.5 N.m (48 lb in).
  157. Install the clutch release fork boot to the manual transaxle case.
    158. Fig 128: Identifying Release Fork Support
    GM2011189Courtesy of GENERAL MOTORS CORP.
  158. Using a deep socket wrench, install the release fork support to the manual transaxle case and tighten to 47 N.m (36 lb ft).
  159. Coat the clutch release bearing assembly with release hub grease, and install it to the clutch release fork sub-assembly.
  160. Apply clutch spline grease to the input shaft spline.
    161. Fig 129: View Of Release Fork With The Release Bearing Assembly
    GM2011203Courtesy of GENERAL MOTORS CORP.
  161. Install the clutch release fork sub-assembly to the input shaft.
scientia non olet · About LEMON Manuals