GM Service Manual Online
For 1990-2009 cars only
  1. Clean all the cover parts with appropriate solvent. Air dry all the parts.
  2. Inspect the cover parts for the following conditions (Refer to
    Object Number: 38465  Size: SF
    (1)Cover
    (2)Bolt
    (3)Bolt
    (4)O-Ring Seal
    (5)Expansion Plug
    (6)Shift Shaft
    (6)Shift Shaft
    (7)3RD/4TH Shift Fork
    (8)Select Control Arm
    (9)Interlock Shift Plate
    (10)1ST/2ND Shift Fork
    (11)Shift Fork Insert
    (12)1ST/2ND Shift Fork Plate
    (13)Roll Pin
    (80)Control Lever Housing
    (81)Shift Lever Damping Sleeve
    (82)Offset Shift Lever
    (83)Zinc Slotted Spring Pin
    (84)Shift Detent Ball Spring
    (85)9.525 mm (0.375 in) Steel Ball
  3. • A worn or damaged shift shaft
    • Smooth movement of the shift shaft in the cover bores
    • Cracks
    • Worn or missing shift fork inserts
    • Unusual wear or damage
    • Burrs or nicks

    Object Number: 38541  Size: SH
  4. Inspect the selector plates control surfaces.

  5. Object Number: 38543  Size: SH
  6. Examine the shift forks and the synchronizer sleeve mating surfaces.
  7. Replace worn or damaged cover parts.
  8. Replace a burred or nicked part that cannot be reconditioned by hand. Use a soft stone or crocus cloth.
  9. Inspect the machined mating surfaces for flatness. Check the mating surfaces with a straight edge.