Transmission Assemble Four Wheel Drive

Tools Required

Important: Some parts require an assembly lubricant. Use TRANSJEL or equivalent.




1. Install the pilot bearing into the input shaft.

•	Turn the small diameter of the bearing cage toward the input shaft.

•	Retain the bearing with TRANSJEL or equivalent.




2. Install the following parts on the assembly fixture J 36515-15 and J 36515 :

2.1.	The input shaft

2.2.	The pilot bearing

2.3.	The synchronizer ring

2.4.	The mainshaft assembly




3. Install the following parts on the mainshaft and on the assembly fixture tool J 36515-16 :

3.1.	The countershaft assembly (1)

3.2.	The reverse idler assembly (2)

3.3.	The 1st/2nd speed gear shift fork (3)

3.4.	The 5th/reverse speed gear shift fork (4)




4. Apply TRANSJEL or equivalent to the countershaft bearing.

Important: Press each bearing roller towards the countershaft race. This will secure them for easier assembly.




5. Install the countershaft bearing on the countershaft. Use TRANSJEL or equivalent in order to retain the bearing. The smaller diameter of the bearing cage goes into the bearing race of the housing.

Important: Bring the housing straight down. If you feel resistance at about 7 mm (¼ in), then the counter shaft bearing rollers are cocked. Repeat the procedure. Do not force the housing down.




6. Install the rear housing assembly.

6.1.	Make sure the reverse idler shaft is lined up with the hole in the case.

6.2.	Rotate the housing back and forth while pulling down.




7. Install a new output shaft bearing snap ring.



8. Install the seal protector tool J 36502-2A on the output shaft.



9. Install the rear housing main shaft oil seal. Use J 36502 .



10. Remove the seal protector J 36502-2A .



11. Fill the space between the seal lip with chassis grease. Use GM P/N 1052497 or equivalent.



12. Lay the rear housing assembly down on the workbench. Remove J 36515 , J 36515-15 , and J 36515-16 from the housing.



13. Apply pipe sealant with Teflon™ GM P/N 1052080 or equivalent to the bolt-hole.



14. Apply threadlocker GM P/N 12345382 or equivalent to the bolt threads.



15. Install the following components:

15.1.

The idler shaft support

15.2.

The idler shaft bolts

15.3.

Line up the bolt threads in the idler shaft support with the bolt hole.

15.4.

Hold the reverse idler shaft against the idler support while tightening the bolts.

Tighten
Tighten the bolts to 22 N·m (16 lb ft).




16. Install J 8763-21 , J 8763-02 , and J 36824 on the transmission housing.



17. Install the 3rd/4th sped gear shift fork onto the 3rd/4th speed gear synchronizer sleeve.

Align all three insert notches.




18. Assemble the following parts onto the shift shaft:

18.1.

The 3rd/4th speed gear shift fork. Make the detent reliefs in the shift shaft point out.

18.2.

The shift lever

18.3.

The block-out bushing

18.4.

The 1st/2nd speed gear shift fork

18.5.

The shift socket




19. Slide the shift shaft all the way into the housing.



20. Install a new roll pin into shift lever.

20.1.

Rotate the shift shaft and the shift lever/block-out bushing assembly. Make sure the roll pin holes are aligned and horizontal.

20.2.

Support the shift shaft while installing the roll pin.

20.3.

Install the roll pin flush with the shift lever.




21. Install the detent spring and the ball plunger into the hole in the shift lever.

21.1.

Rotate the shift shaft counterclockwise. The shift lever should be almost into the 5th / Reverse speed gear insert notch.

21.2.

Install the spring and the ball plunger into the shift lever.

21.3.

Rotate the shift shaft until the shift lever aligns with the 3rd / 4th speed gear insert.

Notice: Excessive force peens the shift shaft and damages the shift shaft bearing. This causes increased shift effort.

Important: Use the rear roll pin hole on the M50 transmission.




22. Install the shift socket roll pin.

22.1.

Align the holes in the shift socket and the shift shaft.

22.2.

Drive the roll pin flush with the bottom of the shift socket.




23. Apply gasket maker GM P/N 1052943 or equivalent to both sides of the isolator plate.
24. Install the isolator plate onto the housing.

The thin side of the plate should be on the left side of the transmission housing.




25. Install the shift lever.
26. Install the four bolts.

Tighten
Tighten the bolts to 8.5 N·m (75 lb in).

Important: The smaller diameter of the bearing cage goes into the bearing race.




27. Install the countershaft bearing in the front housing.

27.1.

Apply TRANSJEL or equivalent on the bearing rollers.

27.2.

Press each bearing roller into the cage.

27.3.

Apply TRANSJEL or equivalent to the bearing race on the input shaft.

Important: Bring the housing straight down. If you feel resistance at about 7 mm (¼ in), then the rollers are cocked. Repeat the procedure. Do not force down the housing.




28. Install the front housing.



29. Install the 2 housing dowel pins. Drive the dowel pins into the front housing flange.



30. Install the housing bolts.

•	Do not tighten the bolts.

•	Tip the transmission vertically.




31. Install a new snap ring on the input shaft.

You may need to pull out on the input shaft in order to install the snap ring.

Important: Do not allow the gasket maker material to plug the oil return hole. This reduces oil flow through the input shaft bearing. Premature bearing failure could result from a plugged oil return hole.




32. Apply gasket maker GM P/N 1052943 or equivalent to the inside edge of the bearing retainer bolt hole pattern.



33. Install the following components:

33.1.

The input shaft bearing retainer assembly

Align the oil drain back hole with the hole in the housing.

33.2.

The 6 bolts

Tighten
Tighten the bolts to 8.5 N·m (75 lb in).




34. Apply pipe sealant to the detent plunger plug. Use pipe sealant with Teflon ™ GM P/N 1052080 or equivalent.



35. Install the following components:

35.1.

The shift shaft detent plunger

35.2.

The shift shaft detent spring

35.3.

The plug

Use a brass drift in order to install the plug.




36. Apply pipe sealant to the backup lamp switch threads. Use pipe sealant with Teflon ™ GM P/N 1052080 or equivalent.



37. Install the backup lamp switch assembly.

Tighten
Tighten the switch to 9 N·m (80 lb in).




38. Remove J 8763-02 and J 36824 .



39. Install 2 bottom housing bolts.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).




40. Install the shift shaft block-out bushing pin.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




41. Fill the transmission with lubricant.

41.1.

Refer to Fluid Capacities in General Information.

41.2.

Use Synchromesh Transmission Fluid GM P/N 12345349 or equivalent.

41.3.

Remove the oil fill plug. Use J 36511 .

41.4.

Install the transmission lubricant.

41.5.

Install the oil fill plug

Tighten
Tighten the oil fill plug to 60 N·m (44 lb ft).

Transmission Assemble NV3500

Tools Required

Important: Some parts require an assembly lubricant. Use TRANSJEL or equivalent.




1. Install the pilot bearing into the input shaft.

•	Turn the small diameter of the bearing cage toward the input shaft.

•	Retain the bearing with TRANSJEL or equivalent.




2. Install the following parts on the assembly fixture J 36515-15 and J 36515 :

2.1.	The input shaft (1)

2.2.	The pilot bearing (2)

2.3.	The synchronizer ring (3)

2.4.	The mainshaft assembly (4)




3. Install the following parts on the mainshaft and on the assembly fixture J 36515-16 :

3.1.	The countershaft assembly (1)

3.2.	The reverse idler assembly (2)

3.3.	The 1st/2nd speed gear shift fork (3)

3.4.	The 5th/reverse speed gear shift fork (4)




4. Install the following components:

4.1.	The output shaft bearing assembly (2)

4.2.	A new mainshaft snap ring (1)




5. Heat the reluctor wheel for 7-10 minutes at 120°C (250°F).

Important: Before assembly, heat the bore of the rear main housing output shaft bearing.




6. Install a new vehicle speed sensor reluctor wheel. Use J 6133-A , if necessary.

Important: Press each bearing roller towards the race. This will secure them for easier assembly.




7. Install the countershaft bearing.

•	Use TRANSJEL or equivalent in order to retain the bearing.

•	The smaller diameter of the bearing cage goes into the bearing race of the housing.




8. Install the following components:

8.1.	J 36515-10 through the bolt-holes in the rear housing

8.2.	Screw the threaded cable ends into the output shaft bearing retainer (1).

8.3.	Position the notch in the bearing retainer towards the oil delivery tube assembly (2).




9. Heat the rear main housing bore 3-5 minutes.

Use J 25070 .

Important: Bring the housing straight down. If you feel resistance at about 7 mm (1/4 in), then the counter shaft bearing rollers are cocked. Repeat the procedure. Do not force the housing down.




10. Install the rear housing assembly.

10.1.

Make sure to line up the reverse idler shaft with the hole in the housing.

10.2.

Rotate the housing back and forth while pushing down.

10.3.

Pull up on J 36515-10 while installing the rear housing.




11. Apply pipe sealant with Teflon™ GM P/N 1052080 or equivalent to the bolt holes of the rear housing.



12. Apply GM P/N 12345382 threadlocker to the bolt threads.



13. Install one rear bearing retainer bolt in the open hole. Do not tighten the bolt. This will hold the bearing retainer plate in place when the cables are removed.



14. Remove one J 36515-10 at a time and replace with bearing retainer bolts.

Tighten
Tighten the rear bearing retainer bolts to 22 N·m (16 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




15. Lay the rear housing assembly down on the workbench. Remove J 36515 , J 36515-15 , and J 36515-16 from the housing.



16. Apply pipe sealant with Teflon™ GM P/N 1052080 or equivalent to the bolt-hole.



17. Apply GM P/N 12345382 threadlocker or equivalent to the bolt threads.



18. Install the following components:

18.1.

The idler shaft support

18.2.

The idler shaft bolts

18.3.

Line up the bolt threads in the idler shaft support with the bolt hole.

18.4.

Hold the reverse idler shaft against the idler support while tightening the bolts.

Tighten
Tighten the bolt to 22 N·m (16 lb ft).




19. Install J 8763-21 , J 8763-02 , and J 36824 on the transmission housing.



20. Install the 3rd/4th speed gear shift fork onto the 3rd/4th speed gear synchronizer sleeve.

Align all three insert notches.




21. Slide the shift shaft through the following parts:

21.1.

The 3rd/4th speed gear shift fork. Ensure that the detent reliefs in the shift shaft point out (1).

21.2.

The shift lever (2).

21.3.

The block-out bushing (3).

21.4.

The 1st/2nd speed gear shift fork (4).

21.5.

The shift socket (5).




22. Slide the shift shaft all the way into the housing.



23. Install a new short roll pin into the shift lever. The end of the spiral must face toward the direction of the thrust.

23.1.

Rotate the shift shaft and the shift lever/block-out bushing assembly. Make sure the roll pin holes are aligned and horizontal.

23.2.

Support the shift shaft while installing the roll pin.

23.3.

Install the roll pin flush with the shift lever.




24. Install the detent spring and the ball plunger into the hole in the shift lever.

24.1.

Rotate the shift shaft counterclockwise. The shift lever should be almost into the 5th/Reverse speed gear insert notch.

24.2.

Install the spring (1) and the ball plunger (2) into the shift lever.

24.3.

Rotate the shift shaft until the shift lever aligns with the 3rd/4th speed gear insert.

Notice: Excessive force peens the shift shaft and damages the shift shaft bearing. This causes increased shift effort.

Important: Use the rear roll pin hole on the M50 (S/T) transmission and the M65 (C/K) transmission.




25. Install the long shift socket roll pannes end of the spiral must face the direction of the thrust.

25.1.

Align the holes in the shift socket and the shift shaft.

25.2.

Drive the roll pin flush with the bottom of the shift socket.




26. Apply gasket maker GM P/N 1052943 or equivalent to both sides of the isolator plate.
27. Install the isolator plate onto the housing.

The thin side of the plate should be on the left side of the transmission housing.




28. Install the shift lever.
29. Install 4 NEW bolts.

Tighten
Tighten the bolts to 12 N·m (106 lb in).

Important: The smaller diameter of the bearing cage goes into the bearing race.




30. Install the countershaft bearing in the front housing.

30.1.

Apply TRANSJEL or equivalent on the bearing rollers.

30.2.

Press each bearing roller into the cage.

30.3.

Apply TRANSJEL or equivalent to the bearing race on the input shaft.

Important: Bring the housing straight down. If you feel resistance at about 7 mm (¼ in), then the rollers are cocked. Repeat the procedure. Do not force down the housing.




31. Install the front housing.



32. Install a new snap ring on the input shaft. It may be necessary to pull out on the input shaft in order to install the snap ring.



33. Rotate the transmission to a horizontal position.

Install the 2 housing dowel pins.

Drive the dowel pins into the front housing flange.




34. Install the housing bolts. Bolts behind the holding fixture can not be installed at this time.

•	Do not tighten the bolts.

•	Tip the transmission vertically.

Important: Do not allow the gasket maker material to plug the oil return hole. This reduces oil flow through the input shaft bearing. Premature bearing failure could result.




35. Apply gasket maker GM P/N 1052943 or equivalent to the inside edge of the bearing retainer bolt hole pattern.



36. Install the following components:

36.1.

The input shaft bearing retainer assembly (Align the oil drain back hole with the hole in the housing.)

36.2.

The six bolts

Tighten
Tighten the bolts to 8.5 N·m (75 lb in).




37. Apply pipe sealant to the detent plunger plug. Use pipe sealant with Teflon ™ GM P/N 1052080 or equivalent.



38. Install the following components:

38.1.

The shift shaft detent plunger

38.2.

The shift shaft detent spring

38.3.

The plug (Use a brass drift in order to install the plug.)




39. Coat the vehicle speed sensor O-ring with clean transmission lubricant. Use Synchromesh Transmission Fluid GM P/N 12345349 or equivalent.



40. Install the electronic speed sensor:

40.1.

Use a new O-ring.

40.2.

Install the bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




41. Apply pipe sealant to the threads of the backup lamp switch assembly. Use pipe sealant with Teflon™ GM P/N 1052080 or equivalent.



42. Install the backup lamp switch assembly.

Tighten
Tighten the switch to 9 N·m (80 lb in).




43. Remove J 8763-02 and J 36824 .



44. Install 2 bottom housing bolts.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).




45. Install the shift shaft block-out bushing pin.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




46. Fill the transmission with lubricant.

46.1.

Refer to Fluid Capacities in General Information.

46.2.

Use Synchromesh Transmission Fluid GM P/N 12345349 or equivalent.

46.3.

Remove the oil fill plug. Use J 36511 .

46.4.

Install the transmission lubricant.

46.5.

Install the oil fill plug.

Tighten
Tighten the oil fill plug to 60 N·m (44 lb ft).

Transmission Assemble NV4500

Tools Required

1. Install the following parts:

1.1.	The 5th speed gear shift lever

1.2.	The shift lever shaft (The notches that retain the 5th speed gear shift fork are to the outside of the case.)

1.3.	The shift lever retaining pin




2. Install a rubber band in order to hold the 5th speed gear shift lever back out of the way.



3. Install the countershaft front bearing cup. Use the J 38856 .



4. Install the countershaft assembly into the transmission case.



5. Install the countershaft rear bearing. Raise and support the countershaft assembly. Install a wood block between the front of the countershaft and the transmission case. Use the J 22828 .



6. Install the following parts:

6.1.	The reverse idler gear

6.2.	The bearings

6.3.	The spacer

6.4.	The washers

6.5.	The reverse idler gear shaft




7. Install the countershaft rear bearing cup.



8. Install the countershaft shim(s) and the bearing retainer plate.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




9. Measure the countershaft end play. Use the fallowing procedure:

9.1.	Set the dial indicator up on the end of the countershaft.

9.2.	Use a screwdriver or the equivalent to lift the countershaft up and down in order to measure the end play.

9.3.	The countershaft end play should be 0.05-0.15 mm (0.002-0.006 in). Add or remove shim(s) under the bearing retainer plate in order to adjust.

9.4.	Remove the retainer plate bolts.




10. Apply sealant to the bolt threads. Use Loctite™ or Dri-Loc™ 201 or the equivalent.



11. Install the countershaft shim(s) and the bearing retainer plate.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).




12. Install the countershaft bearing cap. When properly installed, the outer lip of the cap will be flush with case. Use the J 38856 .



13. Install the mainshaft assembly into the transmission case.



14. Install the main drive gear bearing and the main drive gear assembly into the transmission case.



15. Apply sealant to the main drive gear bearing retainer mating surface. Use GM P/N 1052942 or the equivalent. Do not seal off the oil hole.



16. Install the main drive gear bearing retainer. Position the retainer with the oil hole at the top-center position. Install the main drive gear bearing retainer bolts.

Tighten

1. Tighten the main drive gear bearing retainer bolts to 31 N·m (23 lb ft).
2. Tighten the mainshaft bearing retainer plate bolts to 35 N·m (26 lb ft).



17. Install the following parts:

17.1.

The mainshaft rear bearing cup

17.2.

The shim(s)

17.3.

The bearing retainer plate

17.4.

The mainshaft bearing retainer plate bolts

Tighten
Tighten the bolts finger tight only.




18. Measure the mainshaft end play using the following procedure:

18.1.

Set the dial indicator up on the end of the mainshaft.

18.2.

Use a screwdriver or the equivalent to lift the mainshaft up and down to measure the end play.

18.3.

The mainshaft end play should be 0.05-0.15 mm (0.002-0.006 in). Add or remove shim(s) under mainshaft bearing retainer plate in order to adjust.

18.4.

Remove the mainshaft bearing retainer plate bolts.




19. Apply sealant to the bolt threads.

Use Loctite® or Dri-Loc® 201 or the equivalent.




20. Install the mainshaft bearing retainer plate bolts.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).




21. Install the following parts:

21.1.

The countershaft thrust washer retainer pin

21.2.

The countershaft thrust washer

21.3.

The 5th speed gear bearings

21.4.

The spacer




22. Install the 5th speed gear assembly onto the 5th speed shift shaft and the countershaft. Slide 5th speed gear fork and the 5th speed gear assembly onto the shift shaft.



23. Install the 5th speed gear clutch gear retainer ring.



24. Install the 5th speed gear shift fork roll pins. Support the fork and drive the roll pins downward from the top of the fork.



25. (4WD models) Install the vibration damper to the mainshaft . Move the synchronizer sleeves to lock the transmission into two gears at once. Use the J 39314 .



26. (4WD models) Install the mainshaft washer and nut. Use the J 38805 .

Tighten
Tighten the mainshaft nut to 441 N·m (325 lb ft).




27. (4WD models) Install the rear oil retainer to the transmission case .

Tighten
Tighten the bolts to 54 N·m (40 lb ft).




28. (RWD models) Install the rear oil retainer to the transmission case.

Tighten
Tighten the bolts to 54 N·m (40 lb ft).




29. (RWD models) Install the following parts:

29.1.

The yoke assembly .

29.2.

The spline seal

29.3.

The washer

29.4.

A new nut. Shift the transmission into 1st gear to aid the tightening of the yoke nut.

Tighten
Tighten the yoke nut to 441 N·m (325 lb ft).

Important: Do not use any lubricant other than Castrol® Syntorq LT transmission fluid or the equivalent. Using other lubricants may cause transmission failure.

30. Fill the transmission with the proper amount of lubricant.



31. Apply sealer to the mating surfaces of the transmission cover. Use GM P/N 1052942 or the equivalent.



32. Install the shift cover to the transmission case.

Tighten
Tighten the bolts to 23 N·m (17 lb ft).




33. Apply sealer to the shift cover side of the shift tower isolator plate. Use GM P/N 1052942 or the equivalent.



34. Install the shift tower isolator plate to the shift cover.

Install the shift tower to the isolator plate.

Install the shift tower to shift cover bolts.

Tighten
Tighten the bolts to 6 N·m (53 lb in).