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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 Disassemble

Transmission Disassemble

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Release Fork With The Release Bearing Assembly
    GM2011203Courtesy of GENERAL MOTORS CORP.
  1. Remove the clutch release fork sub-assembly together with the clutch release bearing assembly from the manual transaxle case.
  2. Remove the clutch release bearing assembly and release bearing hub clip from the clutch release fork sub-assembly.
    3. Fig 2: Identifying Release Fork Support
    GM2011189Courtesy of GENERAL MOTORS CORP.
  3. Remove the release fork support from the manual transaxle case.
  4. Remove the clutch release fork boot from the manual transaxle case.
  5. Remove the bolt and speedometer driven hole cover sub-assembly.
  6. Remove the O-ring.
    7. Fig 3: Locating Manual Transmission Case Bolts
    GM2011184Courtesy of GENERAL MOTORS CORP.
  7. Remove the 2 bolts (1) and selecting bellcrank assembly from the manual transmission case.
    8. Fig 4: Identifying Spring Washer Nut
    GM2011180Courtesy of GENERAL MOTORS CORP.
  8. Remove the nut (1) and spring washer.
    9. Fig 5: Removing Bolt
    GM2010671Courtesy of GENERAL MOTORS CORP.
  9. Remove the nut and spring washer.
  10. Remove the control shift lever.
    11. Fig 6: Identifying Manual Transmission Case, Control Shaft Cover & Bolts
    GM2011169Courtesy of GENERAL MOTORS CORP.
  11. Remove the 4 bolts (1) and control shaft cover from the manual transmission case.
    12. Fig 7: Identifying Clutch Tube Bracket Bolt
    GM2011166Courtesy of GENERAL MOTORS CORP.
  12. Remove the bolt and No. 2 clutch tube bracket (1).
    13. Fig 8: Placing Manual Transaxle Assembly On Wooden Blocks
    GM2010677Courtesy of GENERAL MOTORS CORP.
  13. Place the manual transaxle assembly on wooden blocks.
    14. Fig 9: Identifying Manual Transmission Case No. 1 Lock Ball Assembly
    GM2011153Courtesy of GENERAL MOTORS CORP.
  14. Remove the No. 1 lock ball assembly (1) from the manual transmission case.
    15. Fig 10: Locating Manual Transmission Case Shift Gate Pin
    GM2011150Courtesy of GENERAL MOTORS CORP.
  15. Remove the shift gate pin (1) from the manual transmission case.
    16. Fig 11: View Of Manual Transmission Breather Plug
    GM2011149Courtesy of GENERAL MOTORS CORP.
  16. Remove the manual transmission breather plug (1).
    17. Fig 12: View Of Shift And Select Lever Shaft Assembly
    GM2011144Courtesy of GENERAL MOTORS CORP.
  17. Remove the shift and select lever shaft assembly from the manual transmission case.
    18. Fig 13: Identifying Back-Up Light Switch Assembly
    GM2011147Courtesy of GENERAL MOTORS CORP.
  18. Remove the back-up light switch assembly (1) and gasket from the manual transmission case.
    19. Fig 14: View Of Manual Transmission Case
    GM2010693Courtesy of GENERAL MOTORS CORP.
  19. Remove the manual transmission filler plug and gasket from the manual transmission case.
    20. Fig 15: Identifying Drain Plug
    GM2011139Courtesy of GENERAL MOTORS CORP.
  20. Remove the drain plug (1) and gasket from the manual transmission case.
    21. Fig 16: View Of Manual Transmission Case Cover Bolts
    GM2010699Courtesy of GENERAL MOTORS CORP.
  21. Remove the 10 bolts (1) and manual transmission case cover from the manual transmission case.
    22. Fig 17: Engaging 1ST And 2ND Gears Simultaneously
    GM2011129Courtesy of GENERAL MOTORS CORP.
  22. Engage the 1st and 2nd gears simultaneously.
    23. Fig 18: Using A Punch And A Hammer, Unstake Manual Transmission Output Shaft Rear Set Nut
    GM2010704Courtesy of GENERAL MOTORS CORP.
  23. Using a punch (1) and a hammer, unstake the manual transmission output shaft rear set nut.
    24. Fig 19: Locating Manual Transmission Output Shaft Rear Set Nut
    GM2010705Courtesy of GENERAL MOTORS CORP.
  24. Remove the manual transmission output shaft rear set nut (1) from the output shaft.
  25. Disengage the gears.
    26. Fig 20: Removing Transmission Clutch Hub No. 3 Shaft Snap Ring From Input Shaft
    GM2010706Courtesy of GENERAL MOTORS CORP.
  26. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.
    27. Fig 21: Identifying Shift Fork Set Bolt At No. 3 Gear Shift Fork
    GM2010712Courtesy of GENERAL MOTORS CORP.
  27. Remove the shift fork set bolt (1) from the No. 3 gear shift fork.
    28. Fig 22: Removing No. 3 Transmission Clutch Hub And No. 3 Gear Shift Fork From Input Shaft
    GM2010716Courtesy of GENERAL MOTORS CORP.
  28. Using a suitable puller (1), remove the No. 3 transmission clutch hub and No. 3 gear shift fork from the input shaft.
    29. Fig 23: View Of 5TH Gear From Input Shaft
    GM2011115Courtesy of GENERAL MOTORS CORP.
  29. Remove the 5th gear from the input shaft.
    30. Fig 24: Identifying 5TH Gear Needle Roller Bearing & Input Shaft
    GM2011112Courtesy of GENERAL MOTORS CORP.
  30. Remove the 5th gear needle roller bearing from the input shaft.
    31. Fig 25: Removing 5TH Driven Gear From Output Shaft
    GM2010737Courtesy of GENERAL MOTORS CORP.
  31. Using a suitable puller (1), remove the 5th driven gear from the output shaft.
    32. Fig 26: Identifying Screws At Rear Bearing Retainer
    GM2010739Courtesy of GENERAL MOTORS CORP.
  32. Remove the 7 screws (1) and rear bearing retainer from the manual transmission case.
    33. Fig 27: View Of Rear Bearing Shim Output Shaft
    GM2011101Courtesy of GENERAL MOTORS CORP.
  33. Remove the output shaft rear bearing shim from the output shaft.
    34. Fig 28: View Of Input Shaft Rear Bearing Shaft Snap Ring & Input Shaft
    GM2010743Courtesy of GENERAL MOTORS CORP.
  34. Remove the input shaft rear bearing shaft snap ring from the input shaft.
    35. Fig 29: Removing Shift Fork Shaft Snap Ring From No. 1 Gear Shift Fork Shaft
    GM2010745Courtesy of GENERAL MOTORS CORP.
  35. Remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft.
    36. Fig 30: Removing Shift Fork Shaft Snap Ring From No. 2 Gear Shift Fork Shaft
    GM2010749Courtesy of GENERAL MOTORS CORP.
  36. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the No. 2 gear shift fork shaft.
    37. Fig 31: Identifying Reverse Idler Gear Shaft Bolt And Gasket
    GM2011090Courtesy of GENERAL MOTORS CORP.
  37. Remove the reverse idler gear shaft bolt (1) and gasket.
    38. Fig 32: Identifying Bolts At Manual Transaxle Case
    GM2010754Courtesy of GENERAL MOTORS CORP.
  38. Remove the 3 bolts (1) from the manual transaxle case.
    39. Fig 33: View Of Manual Transmission Case Bolts
    GM2010756Courtesy of GENERAL MOTORS CORP.
  39. Remove the 14 bolts (1) from the manual transmission case.
  40. Tapping with a plastic hammer, remove the manual transmission case.
    41. Fig 34: Identifying Reverse Restrict Pin Plug
    GM2011073Courtesy of GENERAL MOTORS CORP.
  41. Remove the reverse restrict pin plug (1) from the manual transmission case.
    42. Fig 35: Removing Slotted Pin
    GM2010760Courtesy of GENERAL MOTORS CORP.
  42. Using a pin punch and hammer, remove the slotted pin.
    43. Fig 36: Identifying Transmission Oil Baffle And Reverse Restrict Pin Assembly Bolt
    GM2011066Courtesy of GENERAL MOTORS CORP.
  43. Remove the bolt (1), transmission oil baffle and reverse restrict pin assembly.
    44. Fig 37: View Of Manual Transmission Case No. 2 Oil Receiver Pipe Bolt
    GM2011062Courtesy of GENERAL MOTORS CORP.
  44. Remove the bolt (1) and No. 2 oil receiver pipe from the manual transmission case.
    45. Fig 38: Locating Manual Transmission Case No. 1 Oil Receiver Pipe Bolt
    GM2011060Courtesy of GENERAL MOTORS CORP.
  45. Remove the bolt (1) and No. 1 oil receiver pipe from the manual transmission case.
    46. Fig 39: Removing Transmission Magnet From Manual Transaxle Case
    GM2010772Courtesy of GENERAL MOTORS CORP.
  46. Remove the transmission magnet from the manual transaxle case.
    47. Fig 40: View Of Reverse Idler Gear Sub-Assembly & Manual Transaxle Case
    GM2010773Courtesy of GENERAL MOTORS CORP.
  47. Remove the reverse idler gear sub-assembly from the manual transaxle case.
    48. Fig 41: Identifying Reverse Gear, Reverse Idler Thrust Washer & Reverse Idler Gear Shaft
    GM2011054Courtesy of GENERAL MOTORS CORP.
  48. Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft.
    49. Fig 42: Locating Manual Transaxle Case Reverse Shift Arm Bracket Assembly Bolts
    GM2011053Courtesy of GENERAL MOTORS CORP.
  49. Remove the 2 bolts (1) and reverse shift arm bracket assembly from the manual transaxle case.
    50. Fig 43: Identifying No. 1 Gear Shift Fork Shift Fork Set Bolt
    GM2011050Courtesy of GENERAL MOTORS CORP.
  50. Remove the shift fork set bolt (1) from the No. 1 gear shift fork.
    51. Fig 44: View Of No. 1 Gear Shift Fork Shaft & No. 3 Gear Shift Fork Shaft
    GM2010782Courtesy of GENERAL MOTORS CORP.
  51. Pull out the No. 1 gear shift fork shaft (1) while pulling up the No. 3 gear shift fork shaft.
    52. Fig 45: Identifying Shift Fork Shaft Snap Ring & No. 1 Gear Shift Fork Shaft
    GM2010789Courtesy of GENERAL MOTORS CORP.
  52. Remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft.
    53. Fig 46: Identifying Magnetic Pick-Up Tool, Reverse Shift Fork Roller & Reverse Shift Fork
    GM2011036Courtesy of GENERAL MOTORS CORP.
  53. Using a magnetic pick-up tool, remove the reverse shift fork roller from the reverse shift fork.
    54. Fig 47: Identifying Shift Head Set Bolt, No. 2 Gear Shift Fork And No. 1 Gear Shift Head
    GM2010797Courtesy of GENERAL MOTORS CORP.
  54. Remove the shift fork set bolt (1) and shift head set bolt from the No. 2 gear shift fork and No. 1 gear shift head.
    55. Fig 48: Identifying Manual Transaxle Case No. 2 Gear Shift Fork Shaft And No. 1 Gear Shift Head
    GM2010799Courtesy of GENERAL MOTORS CORP.
  55. Remove the No. 2 gear shift fork (2) shaft and No. 1 gear shift head from the manual transaxle case.
    56. Fig 49: Locating No. 1 Gear Shift Fork
    GM2010804Courtesy of GENERAL MOTORS CORP.
  56. Remove the No. 1 gear shift fork (1).
    57. Fig 50: Identifying No. 3 Gear Shift Fork Shaft
    GM2010807Courtesy of GENERAL MOTORS CORP.
  57. Remove the No. 3 gear shift fork shaft (1) from the manual transaxle case.
    58. Fig 51: Removing Shift Fork Shaft Snap Rings From No. 3 Gear Shift Fork Shaft
    GM2010811Courtesy of GENERAL MOTORS CORP.
  58. Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.
  59. Remove the reverse shift fork from the No. 3 gear shift fork shaft.
    60. Fig 52: Identifying No. 2 Gear Shift Fork
    GM2010816Courtesy of GENERAL MOTORS CORP.
  60. Remove the No. 2 gear shift fork (1) from the input shaft assembly.
    61. Fig 53: Tilting Output Shaft
    GM2011019Courtesy of GENERAL MOTORS CORP.
  61. Tilt the output shaft, and then remove the input shaft from the manual transaxle case.
    62. Fig 54: Lifting Differential Case Assembly
    GM2010826Courtesy of GENERAL MOTORS CORP.
  62. Lift the differential case assembly with the output shaft assembly leaned.
  63. Remove the output shaft assembly from the manual transaxle case.
    64. Fig 55: View Of Differential Case Assembly
    GM2010830Courtesy of GENERAL MOTORS CORP.
  64. Remove the differential case assembly from the manual transaxle case.
    65. Fig 56: Identifying Manual Transaxle Case Receiver Bolts
    GM2011010Courtesy of GENERAL MOTORS CORP.
  65. Remove the 3 bolts (1) and manual transaxle case receiver from the manual transaxle case.
    66. Fig 57: Removing Input Shaft Front Bearing (Outer Race) Using A Suitable Puller
    GM2010839Courtesy of GENERAL MOTORS CORP.
  66. Using a suitable puller (1), remove the input shaft front bearing (outer race) from the manual transaxle case.
    67. Fig 58: Removing Front Transaxle Case Cover Oil Seal Using A Suitable Puller
    GM2010844Courtesy of GENERAL MOTORS CORP.
  67. Using a suitable puller (1), remove the front transaxle case cover oil seal from the manual transaxle case.
    68. Fig 59: Removing Output Shaft Front Bearing (Outer Race) Using A Suitable Puller
    GM2010845Courtesy of GENERAL MOTORS CORP.
  68. Using a suitable puller (1), remove the output shaft front bearing (outer race) from the manual transaxle case.
    69. Fig 60: Output Shaft Cover At Manual Transaxle Case
    GM2010849Courtesy of GENERAL MOTORS CORP.
  69. Remove the output shaft cover from the manual transaxle case.
    70. Fig 61: Removing Output Shaft Rear Bearing From Manual Transmission Case (Outer Race) Using A Suitable Driver And A Hammer
    GM2010850Courtesy of GENERAL MOTORS CORP.
  70. Using a suitable driver (1) and a hammer, remove the output shaft rear bearing from the manual transmission case (outer race).
    71. Fig 62: Removing Transmission Case Oil Seal From Manual Transmission Case Using A Suitable Puller
    GM2010851Courtesy of GENERAL MOTORS CORP.
  71. Using a suitable puller (1), remove the transmission case oil seal from the manual transmission case.
    72. Fig 63: Removing Transaxle Case Oil Seal
    GM2010854Courtesy of GENERAL MOTORS CORP.
  72. Using a screwdriver, remove the transaxle case oil seal.
    73. Fig 64: Removing Front Differential Case Front Tapered Roller Bearing (Outer Race) Using A Brass Bar And A Hammer
    GM2010856Courtesy of GENERAL MOTORS CORP.
  73. Using a brass bar and a hammer, remove the front differential case front tapered roller bearing (outer race) from the manual transaxle case.
    74. Fig 65: Identifying Puller, Front Differential Case, Front Tapered Roller Bearing & Front Differential Case
    GM2010858Courtesy of GENERAL MOTORS CORP.
  74. Using a suitable puller (1), remove the front differential case front tapered roller bearing from the front differential case.
    75. Fig 66: Removing Front Differential Case Rear Tapered Roller Bearing (Outer Race) And Front Differential Case Rear Shim
    GM2010861Courtesy of GENERAL MOTORS CORP.
  75. Using a suitable driver (1) and a hammer, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case.
    76. Fig 67: Removing Front Differential Case Rear Tapered Roller Bearing (Inner Race) From Front Differential Case Using A Suitable Puller
    GM2010866Courtesy of GENERAL MOTORS CORP.
  76. Using a suitable puller (1), remove the front differential case rear tapered roller bearing (inner race) from the front differential case.
    77. Fig 68: Identifying No. 3 Transmission Hub Sleeve At No. 3 Transmission Clutch Hub
    GM2010870Courtesy of GENERAL MOTORS CORP.
  77. Remove the No. 3 transmission hub sleeve (1) from the No. 3 transmission clutch hub.
    78. Fig 69: Removing No. 3 Synchromesh Shifting Key Springs From No. 3 Transmission Clutch Hub
    GM2010874Courtesy of GENERAL MOTORS CORP.
  78. Remove the 2 No. 3 synchromesh shifting key springs (1) from the No. 3 transmission clutch hub while pushing on the No. 3 synchromesh shifting key spring.
    79. Fig 70: Removing Synchronizer Pull Ring Snap Ring Using A Screwdriver
    GM2010877Courtesy of GENERAL MOTORS CORP.
  79. Using a screwdriver, remove the synchronizer pull ring snap ring.
  80. Remove the synchronizer pull ring, No. 5 synchronizer ring outer, No. 5 synchronizer ring inner, and No. 5 synchronizer ring middle from the No. 5 synchronizer ring inner.
    81. Fig 71: Inspecting 5TH Gear Thrust Clearance Using A Dial Indicator
    GM2010879Courtesy of GENERAL MOTORS CORP.
  81. Using a dial indicator, inspect the 5th gear thrust clearance.

    Specifications:  Standard clearance - 0.10-0.65 mm (0.0039-0.0256 in)

    If clearance is not as specified, replace the No. 3 transmission clutch hub, 5th gear, or input shaft rear radial ball bearing.

    82. Fig 72: Inspecting 5TH Gear Radial Clearance
    GM2010890Courtesy of GENERAL MOTORS CORP.
  82. Using a dial indicator, inspect the 5th gear radial clearance.

    Specifications:  Standard clearance - 0.009-0.050 mm (0.0004-0.0020 in)

    If clearance is not as specified, replace the 5th gear, 5th gear needle roller bearing, or input shaft.

  83. Using a caliper gage, measure the inside diameter of the reverse idler gear.

    Specifications: 

    • Standard inside diameter - 20.056-20.074 mm (0.7896-0.7903 in)
    • Maximum inside diameter - 20.074 mm (0.7903 in)

  84. If the inside diameter exceeds the maximum, replace the reverse idler gear.
    85. Fig 73: Measuring Outside Diameter Of Reverse Idler Gear Shaft
    GM2010899Courtesy of GENERAL MOTORS CORP.
  85. Using a micrometer, measure the outside diameter of the reverse idler gear shaft.

    Specifications: 

    • Standard outside diameter - 19.984-20.000 mm (0.7868-0.7874 in)
    • Minimum outside diameter - 19.984 mm (0.7868 in)

  86. If the outside diameter is less than the minimum, replace the reverse idler gear shaft.
    87. Fig 74: Inspecting Sliding Condition Between No. 3 Transmission Clutch Hub And No. 3 Transmission Hub Sleeve
    GM2010901Courtesy of GENERAL MOTORS CORP.
  87. Inspect the sliding condition between the No. 3 transmission clutch hub and the No. 3 transmission hub sleeve.
  88. Inspect the tip of the spline gear on the No. 3 transmission hub sleeve for wear.
    89. Fig 75: Measuring Width Of The No. 3 Transmission Hub Sleeve Groove & Thickness Of Claw On No. 3 Gear Shift Fork, & Calculate Clearance
    GM2010903Courtesy of GENERAL MOTORS CORP.
  89. Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove and the thickness of the claw on the No. 3 gear shift fork, and calculate the clearance.

    Specifications:  Standard clearance - 0.15-0.35 mm (0.0059-0.0138 in) (A-B)

    If clearance is not as specified, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork with new ones.

    90. Fig 76: Measuring Inside Diameter Of 5TH Gear
    GM2010917Courtesy of GENERAL MOTORS CORP.
  90. Using a caliper gage, measure the inside diameter of the 5th gear.

    Specifications: 

    • Standard inside diameter - 34.981-34.997 mm (1.3772-1.3778 in)
    • Maximum inside diameter - 34.997 mm (1.3778 in)

  91. If the inside diameter exceeds the maximum, replace the 5th gear.
    92. Fig 77: Checking That No. 5 Synchronizer Ring Middle Rotates Smoothly
    GM2010919Courtesy of GENERAL MOTORS CORP.
  92. Check that the No. 5 synchronizer ring middle rotates smoothly.
    93. Fig 78: Checking That No. 5 Synchronizer Ring Middle Does Not Rotate While Pushing It Against No. 3 Clutch Hub
    GM2010929Courtesy of GENERAL MOTORS CORP.
  93. Check that the No. 5 synchronizer ring middle does not rotate while pushing it against the No. 3 clutch hub.
    94. Fig 79: Holding Input Shaft Assembly In A Vise Using Aluminum Plates
    GM2011210Courtesy of GENERAL MOTORS CORP.
  94. Hold the input shaft assembly in a vise using aluminum plates.
  95. Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.
    96. Fig 80: Removing Input Shaft Rear Bearing And 4Th Gear Using A Press
    GM2011214Courtesy of GENERAL MOTORS CORP.
  96. Using a press (1), remove the input shaft rear bearing and 4th gear.
    97. Fig 81: Identifying 4Th Gear Needle Roller Bearing
    GM2011216Courtesy of GENERAL MOTORS CORP.
  97. Remove the 4th gear needle roller bearing from the input shaft.
    98. Fig 82: View Of No. 4 Synchronizer Ring & No. 2 Transmission Clutch Hub
    GM2011221Courtesy of GENERAL MOTORS CORP.
  98. Remove the No. 4 synchronizer ring from the No. 2 transmission clutch hub.
    99. Fig 83: Identifying 4Th Gear Bearing Spacer & No. 2 Transmission Clutch Hub
    GM2011224Courtesy of GENERAL MOTORS CORP.
  99. Remove the 4th gear bearing spacer from the No. 2 transmission clutch hub.
    100. Fig 84: Removing No. 2 Clutch Hub Setting Shaft Snap Ring From Input Shaft Using 2 Screwdrivers And A Hammer
    GM2011227Courtesy of GENERAL MOTORS CORP.
  100. Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.
    101. Fig 85: Removing No. 2 Transmission Clutch Hub And 3Rd Gear From Input Shaft Using A Press
    GM2011233Courtesy of GENERAL MOTORS CORP.
  101. Using a press (1), remove the No. 2 transmission clutch hub and 3rd gear from the input shaft.
    102. Fig 86: View Of 3Rd Gear Needle Roller Bearing & Input Shaft
    GM2011480Courtesy of GENERAL MOTORS CORP.
  102. Remove the 3rd gear needle roller bearing from the input shaft.
    103. Fig 87: Removing No. 3 Synchronizer Ring From 3Rd Gear
    GM2011245Courtesy of GENERAL MOTORS CORP.
  103. Remove the No. 3 synchronizer ring from the 3rd gear.
    104. Fig 88: Removing No. 2 Transmission Hub Sleeve, No. 2 Synchromesh Shifting Keys, And No. 2 Synchromesh Shifting Key Springs
    GM2011269Courtesy of GENERAL MOTORS CORP.
  104. Remove the No. 2 transmission hub sleeve, 3 No. 2 synchromesh shifting keys, and 3 No. 2 synchromesh shifting key springs from the No. 2 transmission clutch hub.
    105. Fig 89: Removing Input Shaft Front Bearing (Inner Race) From Input Shaft Using A Press
    GM2011271Courtesy of GENERAL MOTORS CORP.
  105. Using a press, remove the input shaft front bearing (inner race) from the input shaft.
    106. Fig 90: Measuring 4Th Gear Thrust Clearance
    GM2011276Courtesy of GENERAL MOTORS CORP.
  106. Using a feeler gage, measure the 4th gear thrust clearance.

    Specifications::  Standard clearance - 0.10-0.57 mm (0.0039-0.0224 in)

    If the clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear, or input shaft rear radial ball bearing.

    107. Fig 91: Measuring 3Rd Gear Thrust Clearance
    GM2011290Courtesy of GENERAL MOTORS CORP.
  107. Using a dial indicator, measure the 3rd gear thrust clearance.

    Specifications::  Standard clearance - 0.10-0.35 mm (0.0039-0.0138 in)

    If the clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear, or input shaft.

    108. Fig 92: Measuring 4Th Gear Radial Clearance
    GM2011298Courtesy of GENERAL MOTORS CORP.
  108. Using a dial indicator, measure the 4th gear radial clearance.

    Specifications: 

    • Standard clearance, KOYO made bearing - 0.009-0.053 mm (0.0004-0.0021 in)
    • Standard clearance, NSK made bearing - 0.009-0.051 mm (0.0004-0.0020 in)

  109. If clearance is out of specification, replace the 4th gear, needle roller bearing, or input shaft.
    110. Fig 93: Measuring 3Rd Gear Radial Clearance
    GM2011307Courtesy of GENERAL MOTORS CORP.
  110. Using a dial indicator, measure the 3rd gear radial clearance.

    Specifications: 

    • Standard clearance, KOYO made bearing - 0.009-0.053 mm (0.0004-0.0021 in)
    • Standard clearance, NSK made bearing - 0.009-0.051 mm (0.0004-0.0020 in)

  111. If clearance is out of specification, replace the 3rd gear, needle roller bearing, or input shaft.
    112. Fig 94: Inspecting Shaft For Runout
    GM2011311Courtesy of GENERAL MOTORS CORP.
  112. Using V-blocks and a dial indicator, inspect the shaft for runout.

    Specification:  Maximum runout - 0.03 mm (0.0012 in)

    If the runout exceeds the maximum, replace the input shaft.

    113. Fig 95: Measuring Inside Diameter Of 4Th Gear
    GM2011317Courtesy of GENERAL MOTORS CORP.
  113. Using a cylinder gage, measure the inside diameter of the 4th gear.

    Specifications: 

    • Standard inside diameter - 42.009-42.025 mm (1.6539-1.6545 in)
    • Maximum inside diameter - 42.025 mm (1.6545 in)

  114. If the inside diameter exceeds the maximum, replace the 4th gear.
  115. Using a cylinder gage, measure the inside diameter of the 3rd gear.

    Specifications: 

    • Standard inside diameter - 43.009-43.025 mm (1.6933-1.6939 in)
    • Maximum inside diameter - 43.025 mm (1.6939 in)

  116. If the inside diameter exceeds the maximum, replace the 3rd gear.
    117. Fig 96: Turning No. 4 Synchronizer Ring In One Direction While Pushing It Against 4Th Gear Cone
    GM2011455Courtesy of GENERAL MOTORS CORP.
  117. Coat the 4th gear cone with gear oil. Turn the No. 4 synchronizer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks. If the No. 4 synchronizer ring does not lock, replace the ring or the 4th gear.
    118. Fig 97: Measuring Clearance Between No. 4 Synchronizer Ring Back And 4Th Gear Spline End
    GM2011460Courtesy of GENERAL MOTORS CORP.
  118. Using a feeler gage, measure the clearance between the No. 4 synchronizer ring back and 4th gear spline end.

    Specifications::  Standard clearance - 0.7-1.45 mm (0.0276-0.0570 in)

    119. Fig 98: Turning Synchronizer Outer Ring In One Direction While Pushing It Against 3Rd Gear Cone
    GM2011462Courtesy of GENERAL MOTORS CORP.
  119. Coat the 3rd gear cone with gear oil. Turn the synchronizer outer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks.

    If the synchronizer outer ring does not lock, replace the ring or the 3rd gear.

    120. Fig 99: Measuring Clearance Between No. 3 Synchronizer Ring Back And 3Rd Gear Spline End
    GM2011467Courtesy of GENERAL MOTORS CORP.
  120. Using a feeler gage, measure the clearance between the No. 3 synchronizer ring back and 3rd gear spline end.

    Specifications::  Standard clearance - 0.65-1.75 mm (0.0276-0.0689 in)

    If the clearance is out of specification, replace the No. 3 synchronizer ring.

    121. Fig 100: Inspecting Sliding Condition Between No. 2 Transmission Hub Sleeve & No. 2 Transmission Clutch Hub
    GM2011111Courtesy of GENERAL MOTORS CORP.
  121. Inspect the sliding condition between the No. 2 transmission hub sleeve and No. 2 transmission clutch hub.
  122. Inspect the tip of the spline gear on the No. 2 transmission hub sleeve for wear. If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.
    123. Fig 101: Removing Output Shaft Rear Bearing (Inner Race) & 4Th Driven Gear Using A Press
    GM2011517Courtesy of GENERAL MOTORS CORP.
  123. Using a press (1), remove the output shaft rear bearing (inner race) and 4th driven gear.
    124. Fig 102: View Of Output Gear Spacer From Output Shaft
    GM2011520Courtesy of GENERAL MOTORS CORP.
  124. Remove the output gear spacer from the output shaft.
    125. Fig 103: Removing 3Rd Driven Gear And 2Nd Gear From Output Shaft Using A Press
    GM2011522Courtesy of GENERAL MOTORS CORP.
  125. Using a press (1), remove the 3rd driven gear and 2nd gear from the output shaft.
    126. Fig 104: View Of No. 2 Synchronizer Ring Set From No. 1 Transmission Clutch Hub
    GM2011533Courtesy of GENERAL MOTORS CORP.
  126. Remove the No. 2 synchronizer ring set from the No. 1 transmission clutch hub.
    127. Fig 105: View Of 2Nd Gear Needle Roller Bearing & Output Shaft
    GM2011535Courtesy of GENERAL MOTORS CORP.
  127. Remove the 2nd gear needle roller bearing from the output shaft.
    128. Fig 106: View Of 2Nd Gear Bearing Spacer & Output Shaft
    GM2011779Courtesy of GENERAL MOTORS CORP.
  128. Remove the 2nd gear bearing spacer from the output shaft.
    129. Fig 107: Locating 2Nd Gear Bushing
    GM2011776Courtesy of GENERAL MOTORS CORP.
  129. Remove the 2nd gear bushing from the output shaft.
    130. Fig 108: Identifying 2Nd Gear Bushing Ball
    GM2011774Courtesy of GENERAL MOTORS CORP.
  130. Using a magnetic pick-up tool, remove the 2nd gear bushing ball (1) from the output shaft.
    131. Fig 109: Removing No. 1 Transmission Clutch Hub And 1St Gear From Output Shaft Using A Press
    GM2011548Courtesy of GENERAL MOTORS CORP.
  131. Using a press (1), remove the No. 1 transmission clutch hub and 1st gear from the output shaft.
    132. Fig 110: View Of No. 1 Synchronizer Ring Set
    GM2011767Courtesy of GENERAL MOTORS CORP.
  132. Remove the No. 1 synchronizer ring set from the 1st gear.
    133. Fig 111: View Of 1St Gear Needle Roller Bearing & Output Shaft
    GM2011768Courtesy of GENERAL MOTORS CORP.
  133. Remove the 1st gear needle roller bearing from the output shaft.
    134. Fig 112: Removing Output Shaft Front Bearing (Inner Race) From Output Shaft Using A Press
    GM2011739Courtesy of GENERAL MOTORS CORP.
  134. Using a press (1), remove the output shaft front bearing (inner race) from the output shaft.
    135. Fig 113: Removing No. 1 Synchromesh Shifting Key Springs From Reverse Gear
    GM2011740Courtesy of GENERAL MOTORS CORP.
  135. Remove the No. 1 transmission clutch hub, 3 No. 1 synchromesh shifting keys, and 3 No. 1 synchromesh shifting key springs from the reverse gear.
    136. Fig 114: Measuring 1St Gear Thrust Clearance
    GM2011742Courtesy of GENERAL MOTORS CORP.
  136. Using a feeler gage, measure the 1st gear thrust clearance.

    Specifications::  Standard clearance - 0.25-0.40 mm (0.0098-0.0157 in)

    If the clearance is out of specification, replace the 1st gear, or No. 1 transmission clutch hub.

    137. Fig 115: Measuring 2Nd Gear Thrust Clearance
    GM2011745Courtesy of GENERAL MOTORS CORP.
  137. Using a dial indicator, measure the 2nd gear thrust clearance.

    Specifications::  Standard clearance - 0.10-0.35 mm (0.0039-0.0138 in)

    138. Fig 116: Inspecting Shaft For Runout
    GM2011750Courtesy of GENERAL MOTORS CORP.
  138. Using V-blocks and a dial indicator, inspect the shaft for runout.

    Specification:  Maximum runout - 0.03 mm (0.0012 in)

    If runout exceeds the maximum, replace the input shaft.

    139. Fig 117: Measuring Inside Diameter Of 2Nd Gear
    GM2011755Courtesy of GENERAL MOTORS CORP.
  139. Using a cylinder gage, measure the inside diameter of the 2nd gear.

    Specifications: 

    • Standard inside diameter - 50.009-50.025 mm (1.9689-1.9695 in)
    • Maximum inside diameter - 50.025 mm (1.9695 in)

  140. If the inside diameter exceeds the maximum, replace the 2nd gear.
  141. Using a cylinder gage, measure the inside diameter of the 1st gear.

    Specifications: 

    • Standard inside diameter - 51.009-51.025 mm (2.0082-2.0089 in)
    • Maximum inside diameter - 51.025 mm (2.0089 in)

  142. If the inside diameter exceeds the maximum, replace the 1st gear.
    143. Fig 118: Turning Synchronizer Ring Set In One Direction While Pushing It Against 2Nd Gear Cone
    GM2011756Courtesy of GENERAL MOTORS CORP.
  143. Coat the 2nd gear cone with gear oil.
  144. Check for wear and damage.
  145. Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.
  146. Check that the ring locks.

    If the synchronizer ring set does not lock, replace the synchronizer ring set.

    147. Fig 119: Measuring Clearance Between Synchronizer Ring And Gear Spline End
    GM2011758Courtesy of GENERAL MOTORS CORP.
  147. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

    Specifications::  Standard clearance - 0.70-1.45 mm (0.0276-0.0571 in)

    If the clearance is less than the minimum, replace the synchronizer ring set.

  148. Coat the 1st gear cone with gear oil.
    149. Fig 120: Checking For Wear And Damage
    GM2011760Courtesy of GENERAL MOTORS CORP.
  149. Check for wear and damage.
  150. Turn the synchronizer ring set in one direction while pushing it against the 1st gear cone.
  151. Check that the ring set locks.

    If the synchronizer ring set does not lock, replace the synchronizer ring set.

    152. Fig 121: Measuring Clearance Between Synchronizer Ring And Gear Spline End
    GM2011761Courtesy of GENERAL MOTORS CORP.
  152. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

    Specifications::  Standard clearance - 0.70-1.45 mm (0.0276-0.0571 in)

    If the clearance is less than the minimum, replace the synchronizer ring set.

    153. Fig 122: Measuring Width Of Reverse Gear Groove And Thickness Of Claw Part On No. 1 Gear Shift Fork
    GM2011762Courtesy of GENERAL MOTORS CORP.
  153. Using vernier calipers, measure the width of the reverse gear groove and thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance.

    Specifications::  Standard clearance - 0.15-0.35 mm (0.0059-0.0138 in) (A-B)

    If the clearance is out of specification, replace the reverse gear and No. 1 gear shift fork with new ones.

    154. Fig 123: Checking Sliding Condition Between No. 1 Transmission Clutch Hub And Reverse Gear
    GM2011763Courtesy of GENERAL MOTORS CORP.
  154. Check the sliding condition between the No. 1 transmission clutch hub and the reverse gear.
  155. Check the tip of the spline gear on the sleeve of the reverse gear for wear.

    If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.

    156. Fig 124: View Of Speedometer Drive Gear From Front Differential Case Assembly
    GM2011790Courtesy of GENERAL MOTORS CORP.
  156. Remove the speedometer drive gear from the front differential case assembly.
    157. Fig 125: Putting Matchmarks On Front Differential Ring Gear And Front Differential Case
    GM2011793Courtesy of GENERAL MOTORS CORP.
  157. Put matchmarks (1) on the front differential ring gear and the front differential case.
    158. Fig 126: View Of Front Differential Case Bolts
    GM2011795Courtesy of GENERAL MOTORS CORP.
  158. Remove the 16 bolts (1).
  159. Using a plastic hammer, remove the front differential case.
    160. Fig 127: Unstaking Staked Part Of Front Differential Case
    GM2011797Courtesy of GENERAL MOTORS CORP.
  160. Unstake the staked part of the front differential case.
    161. Fig 128: Removing Front Differential Pinion Shaft Straight Pin From Front Differential Case
    GM2011798Courtesy of GENERAL MOTORS CORP.
  161. Using a pin punch and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
    162. Fig 129: View Of No. 1 Front Differential Pinion Shaft & Front Differential Case
    GM2011800Courtesy of GENERAL MOTORS CORP.
  162. Remove the No. 1 front differential pinion shaft from the front differential case.
    163. Fig 130: View of Front Differential Gears, Washers & Front Differential Case
    GM2011801Courtesy of GENERAL MOTORS CORP.
  163. Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front differential side gears, and 2 front differential side gear thrust washers from the front differential case.

    Remove the 2 pinion thrust washers and side gear thrust washers while turning the front differential pinion.

    164. Fig 131: Measuring Front Differential Side Gear Backlash
    GM2011803Courtesy of GENERAL MOTORS CORP.
  164. 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 (0.002-0.00798 in)

    If the backlash is out of specification, install proper side gear thrust washers.

    165. Fig 132: Measuring Thickness Of Front Differential Pinion Thrust Washer
    GM2011254Courtesy of GENERAL MOTORS CORP.
  165. Using a micrometer, measure the thickness of the front differential pinion thrust washer.

    Specifications:  Minimum thickness - 0.09 mm (0.035 in)

    If the thickness is less than the minimum, replace the front differential pinion thrust washer.

    166. Fig 133: Measuring Outside Diameter Of No. 1 Front Differential Pinion Shaft
    GM2011807Courtesy of GENERAL MOTORS CORP.
  166. Using a micrometer, measure the outside diameter of the No. 1 front differential pinion shaft.

    Specifications:  Minimum diameter - 17.975 mm (0.70768 in)

    If the outer diameter is less than the minimum, replace the No. 1 front differential pinion shaft.

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