- Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) to each gear shift fork and gear shift head. Join the shift rail assembly to the input shaft and countershaft assembly.
- Install the input shaft, countershaft and shift rails as an assembly in the clutch housing.
- Install the snap ring into the groove of the input shaft radial ball bearing.
- Install the snap ring into the groove of the countershaft radial ball bearing.
- Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the shift rail bolts.
Caution: Refer to Fastener Caution in the Preface section.
- Install the 4 shift rail bolts and tighten to
21 N·m (15 lb ft).
Note: During alignment, ensure that the thread hole of the reverse idler gear shaft (204) aligns with the thread hole of the middle case.
- Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) and install the following components:
| • | The reverse idler gear bearing (136) |
| • | The reverse idler gear (205) with the higher boss facing the rear |
| • | The reverse idler gear shaft (204) with its hole facing outward |
- Apply sealer GM P/N 89020326 (Canadian P/N 89021188) or equivalent to the interface of either case.
- Install the shift shaft selector lever.
Caution: Refer to Machined Surface Damage Caution in the Preface section.
- Apply sealer GM P/N 89020326 (Canadian P/N 89021188) or equivalent to the interface of either case.
- Apply lubricant GM P/N 88862475 (Canadian P/N 88862476 to the shift and select lever shaft bearing.
- Install the intermediate case housing.
- Install the 8 bolts from the clutch housing and the 3 bolts from the middle case. Tighten the bolts to
40 N·m (29 lb ft).
- Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) and install the input shaft bearing (137), blocking ring (121) and the rear output shaft (111).
- Install the oil trough pipe (19).
- Install a NEW gasket (32) and the bolt (35) to secure the reverse idler shaft. Tighten the bolt to
40 N·m (30 lb ft).
- Install the oil trough (20) and the 2 oil trough bolts (37) and tighten to
8.5 N·m (75 lb in).
- Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) to the following components:
| • | The tapered roller bearing outer race |
| • | The cylindrical roller bearing |
| • | The control sub-assembly holes |
- Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) to the following components:
| • | The tapered roller bearing of the output shaft |
| • | The cylindrical roller bearing inner race of counter gear |
- Apply sealer GM P/N 89020326 (Canadian P/N 89021188) or equivalent to the clean interface of either case.
Caution: Refer to Machined Surface Damage Caution in the Preface section.
Note: Use care when installing the rear case housing so that the oil receiver is not damaged.
- Install the rear case housing.
- Install the 10 bolts (27) and retainer (209) to the rear case housing. Tighten the bolts to
40 N·m (29 lb ft).
- Apply lubricant GM P/N 88862475 (Canadian P/N 88862476) and install the lock ball pin (68).
- Install the spring (75) and a NEW plug (36). Tighten the plug to
24.5 N·m (18 lb ft).
- Using
J 35467 tester
, install a NEW clutch housing hole plug (30) into the clutch housing. Tighten the bolt to
39.3 N·m
(29 lb ft).
- Using
J 44731 installer
, install a NEW input shaft seal (12).
- Align and install the main shaft bearing oil slinger (107).
- Grease and install the locking ball (214).
- Align and install the vehicle speed sensor drive gear (212).
- Install a NEW rear output shaft rear bearing spacer (191).
- Apply sealer GM P/N 89020326 (Canadian P/N 89021188) or equivalent to the interface of either case.
- Install the rear extension housing.
- Install the 8 bolts (93) into the rear extension housing (86) and tighten to
29 N·m (21 lb ft).
- Install the dampener (102) and shift lever rod universal joint (40) on the end of the shift control shaft.
Note: Prior to shift lever pin installation, the shift control shaft must be shifted forward into the transmission.
- Position and align the shift lever pin (41) with the hole in the shift lever rod universal joint. Use
DT-49027-3 coil pin installer
and a mallet to install the pin (41) to
the proper depth.
- Install the propshaft flange (108).
- Grease and install a NEW propshaft flange fluid seal (193).
- Install a NEW propshaft flange nut (126).
