Transmission Assemble
SHIFT SHAFT ASSEMBLIES AND GEAR CLUSTERS INSTALLATION^ Tools Required
- J 36850 Transjel(R) Transmission Assembly Lube
1. Lubricate all components as assembly progresses. Use J 36850
2. Install the selective shims. Refer to the Input Shaft, Mainshaft, and Countershaft Shimming under "Shimming Procedures".
3. Install the following parts:
^ The input shaft bearing race
^ The countershaft bearing race
4. Install the input shaft in the adapter plate.
5. Assemble the shift shaft to the mainshaft. Install the mainshaft and the shift shaft assembly.
6. Install the countershaft assembly using the following sequence:
6.1. Lift up the mainshaft assembly enough in order to install the countershaft assembly.
6.2. Install the countershaft assembly.
6.3. Lift the mainshaft assembly enough in order to rotate the input shaft to engage the synchronizer keys with 4th gear blocking ring.
7. Install the 5th/6th and the reverse shift shaft. Align the slots of the shift shaft levers with the interlock plate.
REVERSE LOCKOUT ASSEMBLY ASSEMBLE
CAUTION: The reverse lockout assembly is under spring pressure. Exercise caution when removing the retainer ring, as bodily injury may result.
1. Install the reverse lockout plunger.
2. Install the reverse lockout outer spring.
3. Install the reverse lockout collar.
4. Compress the reverse lockout plunger and the collar in a vise and Install the retainer ring.
5. Install the reverse lockout inner spring.
6. Install the reverse lockout components in the body.
7. Install the retainer ring.
8. Install the O-ring to body.
^ Tools Required
- J 41099 Reverse Solenoid Socket
- J 36850 Transmission Assembly Lubricant
IMPORTANT: Lubricate all components as the assembly progresses. Use J 36850 or the equivalent.
1. Apply sealant at the transmission case to adapter plate mating surface. Use GM P/N 12345739 or the equivalent.
2. Install the ball detent and the spring in the front offset lever
3. Do the following in order to install the transmission case and the offset lever:
3.1. Shift the transmission into NEUTRAL in order to keep the 3rd/4th shift shaft from engaging.
3.2. Install the offset lever.
3.3. Compress the front offset lever together while sliding it onto the shift shaft. This will prevent the spring release of the inner components.
3.4. Slide the transmission case onto the gear clusters and the shift rail components.
4. Apply anaerobic threadlocker GM P/N 12346004 or the equivalent to the threads of the shift lever guide bolts.
5. Install the shift lever guide bolts and pull up on 5th/6th and reverse shift rail assembly. This will help align the slot of the shift interlock plate with the guide bolt hole.
^ Tighten the bolts to 27 Nm (20 ft. lbs.).
6. Install the adapter plate to transmission case bolts.
^ Tighten the bolts to 35 Nm (26 ft. lbs.).
7. Install the offset lever roll pin.
8. Install the shift detent assembly.
^ Tighten the detent assembly to 40 Nm (30 ft. lbs.).
9. Apply sealant GM P/N 12345739 or the equivalent to the mating surface of the cover plate.
10. Install the cover plate and the cover plate bolts.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).
11. Install the reverse lockout body and bolt in the cover plate.
^ Tighten the bolts to 18 Nm (13 ft. lbs.).
12. Install the computer aided gear select solenoid.
^ Tighten the solenoid to 40 Nm (30 ft. lbs.).
COUNTERSHAFT EXTENSION INSTALLATION
1. Position the transmission in the horizontal position.
2. Install the countershaft extension assembly and the 5th/6th shift fork. The splines of the countershaft extension must engage the splines of the countershaft.
3. Install the 5th/6th shift fork retainer ring.
5TH/6TH SPEED DRIVEN GEAR INSTALLATION
^ Tools Required
- J 39441 Gear Installer
- J 39441-10 Gear Installer Adapter
Install the 5th/6th speed driven gear using the J 39441 and J 39441-10. The smaller OD of the gear faces down.
REVERSE SHIFT FORK INSTALLATION
1. Install the reverse shift fork, the synchronizer and the thrust washer.
2. Install a new shift fork retainer ring.
3. Install the reverse synchronizer retainer ring.
REVERSE SPEED GEAR INSTALLATION
1. Install the following parts in order:
1.1. The blocking ring
1.2. The wave washer
1.3. The wave washer so the concave side faces the blocking ring
1.4. The caged needle bearing
1.5. The reverse speed gear
1.6. The thrust washer
1.7. The retainer ring
2. Install the following parts in order:
2.1. The spacer
2.2. The roller bearing
2.3. The spacer
2.4. The roller bearing retainer ring
EXTENSION HOUSING INSTALLATION
1. Install the following parts in order:
1.1. The funnel
1.2. The selective shims.
1.3. The countershaft extension bearing race
2. Install the following parts in order:
2.1. The reverse idler shaft
2.2. The roller bearing
2.3. The reverse idler gear
3. Apply Loctite(R) 272 GM P/N 12345382 or the equivalent to the reverse idler shaft brackets bolt threads.
4. Install the following parts in order:
4.1. The reverse idler shaft bracket
4.2. The reverse idler shaft bracket bolts
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
5. Apply sealant GM P/N 12345739 or the equivalent to the extension housing to the transmission case mating surface.
6. Apply thread sealer GM P/N 12346004 or the equivalent to the top two extension housing bolts.
7. Install the extension housing.
8. Install the extension housing bolts and the transmission bumper.
^ Tighten the bolts to 35 Nm (26 ft. lbs.).
9. Install the vent tube.
10. Install the rear offset shift lever and the isolator cup.
11. Install the rear offset shift lever roll pin. Apply sealant GM P/N 12345739 or the equivalent to the shift lever-to-extension housing mating surface.
12. Install the shifter.
13. Install the shifter bolts.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).