GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 36633 Snap Ring Retainer
    • KM-334 Installer Sleeve
    • KM-552 Fixture
    • KM-554 Installer
    • J 3289-20 (KM 113-2) Holding Fixture

Assembly Procedure


    Object Number: 1251668  Size: SH
  1. Join the mainshaft and the input shaft.
  2. Compress the snap ring at the base of the mainshaft and hold with the J 36633  (1).
  3. Hold the snap ring at the base of the input drive shaft with the snap ring pliers.
  4. Install the mainshaft/input shaft assembly onto the bearing plate.
  5. Release the mainshaft snap ring and the input shaft snap ring.

  6. Object Number: 1251685  Size: SH
  7. Position the 1st-2nd gearshift fork.
  8. Install the 5th gearshift lever into the bearing plate.

  9. Object Number: 1251684  Size: SH
  10. Install the 3rd-4th gearshift rod/fork holding pin.

  11. Object Number: 1251683  Size: SH
  12. Install the support bracket onto the bearing plate.

  13. Object Number: 1251777  Size: SH
  14. Install the 1st-2nd gearshift rod/fork onto the bearing plate.

  15. Object Number: 1251681  Size: SH
  16. Install the 1st-2nd gearshift fork holding pin.

  17. Object Number: 1251678  Size: SH
  18. Install the support bracket bolts.
  19. Tighten
    Tighten the support bracket bolts to 7 N·m (62 lb in).


    Object Number: 1251675  Size: SH
  20. Install the reverse gearshift rod/fork on the bearing plate.

  21. Object Number: 1251674  Size: SH
  22. Install the reverse gearshift rod/fork holding pin.

  23. Object Number: 1251672  Size: SH
  24. Install the rod lock pin and spring into the small plug hole.

  25. Object Number: 1251778  Size: SH
  26. Install the 4th gearshift rod plugs.

  27. Object Number: 1251670  Size: SH
  28. Install the bolts and the 5th gearshift connector onto the bearing plate, using the pawl.
  29. Tighten
    Tighten the 5th gearshift connector bolts to 7 N·m (62 lb in).


    Object Number: 1251780  Size: SH
  30. Install the input drive 5th gear using the KM-554  (2) and the KM-334  (1).

  31. Object Number: 1251668  Size: SH
  32. Install the snap rings securing the 5th drive gear.

  33. Object Number: 1251666  Size: SH
  34. Install the thrust washers, the retaining ring, and the needle bearing into the mainshaft-driven 5th gear assembly.

  35. Object Number: 1251665  Size: SH
  36. Install the brass synchronizer ring onto the mainshaft-driven 5th gear assembly.

  37. Object Number: 1251782  Size: SH
  38. Install the mainshaft-driven 5th gear assembly.
  39. Install the 5th drive gear synchronizer gear and the synchronizer sleeve using KM-554  (1).

  40. Object Number: 1248226  Size: SH
  41. Install the snap ring holding the 5th speed-driven assembly.

  42. Object Number: 1248225  Size: SH
  43. Install the bolts and the 5th gear fork onto the bearing plate.
  44. Tighten
    Tighten the 5th gear fork bolts to 22 N·m (16 lb ft).


    Object Number: 1248221  Size: SH
  45. Remove the bearing plate from the fixture.
  46. Shift the transaxle into the 2nd gear.
  47. Install the bearing plate, with the shafts attached, into the case.

  48. Object Number: 1248220  Size: SH
  49. Install the bearing plate bolts.
  50. Tighten
    Tighten the bearing plate bolts to 22 N·m (16 lb ft).


    Object Number: 1248215  Size: SH
  51. Install the speedometer-driven gear and the speedometer-housing retaining bolt into the transaxle housing.
  52. Tighten
    Tighten the speedometer housing retaining bolt to 4 N·m (35 lb in).


    Object Number: 1248213  Size: SH
  53. Bolt the gearshift lever cover to the KM-552  (2).
  54. Position the fixture into the base J 3289-20  (3) .
  55. Install the gearshift rod (1), the shift finger lever, and the gearshift lever pin.

  56. Object Number: 1248211  Size: SH
  57. Install the snap ring, the bushing, the spring, and the intermediate lever.
  58. Remove the gearshift lever cover from the base and the fixture.
  59. Shift the transaxle into NEUTRAL.

  60. Object Number: 1248207  Size: SH
  61. Install the gearshift lever cover and the gearshift lever cover bolts.
  62. Tighten
    Tighten the gearshift lever cover bolts to 22 N·m (16 lb ft).


    Object Number: 1248217  Size: SH
  63. Install the transaxle cover and the transaxle cover bolts.
  64. Tighten
    Tighten the transaxle cover bolts to 18 N·m (13 lb ft).

  65. Install the transaxle into the vehicle. Refer to Transmission Replacement .