GM Service Manual Online
For 1990-2009 cars only

    Object Number: 38545  Size: SH

    Warning: Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes are inhaled or if skin is exposed to chemicals.

  1. Clean all the parts in a suitable solvent. Air dry all the parts.
  2. Inspect the gear tooth surfaces on all the gear sets for the following conditions:
  3. • Cracks
    • Pitting
    • Nicks
    • Chipped gear teeth
    • High spots -- small shiny spots on the gear teeth mating surfaces
  4. Inspect for damaged splines on the input shaft, mainshaft, and the countershaft extension.
  5. Remove nicks and burrs with a soft stone or a crocus cloth.
  6. Replace a burred or nicked part that cannot be reconditioned by hand.
  7. Replace gears and gear assemblies that are worn or damaged.