V. Transmission Assemble

ASSEMBLY PROCEDURE


^ Tools Required
- J 8001 Dial Indicator Set
- J 8092 Driver Handle
- J 22912-01 Bearing And Gear Puller
- J 6133-01 Installer
- J 37357 Countershaft Bearing and Race Remover and Installer
- J 37372 Synchronizer and Gear Installer





1. Install the countershaft front bearing. Use the J 37357, the J 22912-01, and a hydraulic press.

NOTICE: Support the countershaft while installing the rear countershaft bearing. The transmission case can be permanently distorted if the countershaft is not supported.





2. Install the countershaft in the case.
3. Install the rear countershaft bearing onto the countershaft. Use the J 37372 and a hydraulic press. Support the countershaft with the J 37357.





4. Install the rear countershaft bearing race.





5. Install the reverse idler gear and a new rubber O-ring on the reverse idler gear shaft. The shift lever groove should face the rear of the case.





6. Install a new roll pin into the reverse idler gear shaft.





7. Install the countershaft retainer and the countershaft retainer bolt. Do not install the countershaft shims.
^ Tighten the countershaft retainer bolts to 20 Nm (15 ft. lbs.).





8. Measure the countershaft end play as follows:
8.1. Use the J 8001.
8.2. Record the end play measurement.
8.3. Remove the countershaft retainer.
8.4. Select a shim pack in order to provide 0.00-0.10 mm (0.00-0.004 inch) end play.
8.5. Do not preload the bearing with shims larger than the original end play measurement.
9. Install the countershaft shims, the countershaft retainer, and the countershaft retainer bolts.
^ Tighten the countershaft retainer bolts to 20 Nm (15 ft. lbs.).





10. Bend the staking tabs over the four bolts.





11. Install the reverse shift fork in the case.





12. Install the mainshaft assembly.





13. Install the rear mainshaft bearing race.





14. Install the main drive gear. Engage the 3rd-4th gear synchronizer sleeve and the blocking ring.





15. Install the bearing race in the input gear bearing retainer. Do not install the shims.





16. Install the main drive gear bearing retainer.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).





17. Install the 5th speed driven gear.





18. Install the shift shaft assembly into the case and through the reverse shift fork and lock spring.





19. Align the marks on the 5th speed gear synchronizer that were made during disassembly.





20. Assemble the 5th speed gear synchronizer. Install the blocking ring and the 5th speed gear synchronizer in the 5th speed gear shift fork.





21. Install the shift fork and the 5th speed gear synchronizer assembly.





22. Install the 5th speed gear synchronizer retainer.
23. Install a new retainer ring.





24. Install the oiling funnel into the rear of the countershaft.





25. Connect the shift lever return spring at the side of the case. Make sure the reverse shift fork pin and the 5th speed gear shift rail pin are engaged with the shift lever.





26. Coat the 5th speed gear/reverse lever pivot bolt threads with pipe thread sealant. Use GM P/N 12346004 or the equivalent.
27. Install the 5th speed gear/reverse lever pivot bolt.
^ Tighten the bolt to 27 Nm (20 ft. lbs.).





28. Install the 5th speed/reverse shift lever retainer clip.
29. Coat the threads of the backup lamp switch with pipe thread sealant. Use GM P/N 12346004 or the equivalent.





30. Install the backup lamp switch.
^ Tighten the backup lamp switch to 38 Nm (28 ft. lbs.).





31. Install the speedometer reluctor and the reluctor retainer ball. Use the J 6133-01.





32. Install a new 5th gear retainer ring.





33. Apply a 3 mm (1/8 inch) bead of RTV Sealant to the cover assembly. Use GM P/N 12345739 or the equivalent.





34. Install the cover while aligning the shift forks and the synchronizer sleeves:
34.1. Position the mainshaft synchronizers in neutral. The mainshaft should rotate freely.
34.2. Position the cover assembly shift forks in neutral (center).
34.3. Install the two dowel bolts.
34.4. Install the remaining cover bolts.
^ Tighten the cover bolts to 13 Nm (115 inch lbs.).





35. Apply a 3 mm (1/8 inch) diameter bead of RTV Sealant to extension housing sealing surface. Use GM P/N 12345739 or equivalent.





36. Coat the detent spring with petroleum jelly. Install the detent spring in the offset lever.





37. Lubricate the detent plate and install the detent ball in the neutral position on the plate. Position the offset lever in the extension housing with the spring over the detent ball.





38. Slide the lever and the extension housing into position as an assembly. Press downward on the offset lever to compress the detent spring. Push the lever and the housing into position.





39. Install the extension housing vent, if removed.





40. Apply pipe thread sealant to the threads of the bolts. Use GM P/N 12346004 or the equivalent.
41. Install the extension housing bolts.
^ Tighten the bolts to 30 Nm (22 ft. lbs.).





42. Install a new roll pin into the offset lever and the shift shaft.





43. Install the damper sleeve in the offset lever.





44. Measure the mainshaft end play as follows:
44.1. Turn the transmission case on end.
44.2. Install the J 8001.
44.3. Rotate the mainshaft and zero the dial indicator.
44.4. Pull upward on the mainshaft until the end play is removed.
44.5. Record the measurement.
44.6. The ideal mainshaft end play is zero (0.00). Plus or minus 0.02 mm (0.001 inch) is allowable.
44.7. Select a shim pack equal to the dial indicator measurement recorded.





45. Remove the main drive gear bearing retainer and the front bearing race. Install the necessary shims and reinstall the bearing race.





46. Apply a 3 mm (1/8 inch) diameter bead of RTV Sealant on the case mating surface of main drive gear bearing retainer. Use GM P/N 12345739 or the equivalent.





47. Apply pipe thread sealant to the threads of the main drive gear retainer bolts. Use GM P/N 12346004 or the equivalent.





48. Install the main drive gear bearing retainer.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).





49. Apply pipe thread sealant to the threads of the oil drain plug and the oil fill plug. Use GM P/N 12346004 or the equivalent.





50. Install the oil drain plug.
^ Tighten the oil drain plug to 27 Nm (20 ft. lbs.).

NOTICE: Use only DEXRON(R) III GM P/N 12346143 Automatic Transmission Lubricant for this manual transmission assembly. Other lubricants or additives may damage the blocker ring friction material or the adhesives.





51. Install new transmission fluid.





52. Install the oil fill plug.
^ Tighten the oil fill plug to 27 Nm (20 ft. lbs.).