GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Chevy C Silverado - 2WD 🢒 Body and Accessories 🢒 Wiring Systems 🢒 Transmission Disassemble

Transmission Disassembly

Tools Required

    • J 3289-20 Holding Fixture
    • J 8763-B Holding Fixture and Base
    • J 8763-21 Balance Bracket for C-Clamp
    • J 21427-A Speedometer Gear Puller Adapter
    • J 22912-B Split Plate Bearing Puller
    • J 23907 Slide Hammer
    • J 24420-C Harmonic Balancer Puller
    • J 26941 Bearing/Bushing Remover
    • J 36509 Detent Spring Plug Remover
    • J 36515 Assembly Pallet
    • J 36515-15 Mainshaft Adapter
    • J 36515-16 Countershaft Adapter
    • J 36511 Oil Fill/Drain Plug Hex Bit (17 mm)
    • J 36183 Press Tube
    • J 36184 Press Tube Reducer
    • J 36507 Shift Shaft Detent Bushing Remove and Installer
    • J 36800 Shift Rail Bushing Remover
    • J 36824 Transmission Adapters
    • J 36825 Output Shaft Oil Seal Remover

    Object Number: 4776 Size: SH
  1. Remove the two lower housing bolts.

    2. Object Number: 626284 Size: SH

    Important: The J 3289-20 requires mounting securely on a sturdy workbench.

  2. Assemble the transmission holding fixture to the transmission.
    3. 2.1. Install the J 36824  (1) and the J 8763-B  (4) to the J 8763-21  (3).
    2.2. Install the J 8763-21  (3) to the J 3289-20  (2).
    2.3. Place the transmission in the holding fixture and adjust the J 36824  (1) and the J 8763-B  (4) to support the transmission.

    Object Number: 548103 Size: SH
  3. Using J 36511 , remove the oil fill plug.

    4. Object Number: 4843 Size: SH
  4. Place a suitable container under the transmission assembly in order to drain the remaining transmission fluid.
  5. Using J 36511 , remove the oil drain plug.
  6. Remove the gasket material from the housing.

    7. Object Number: 4775 Size: SH
  7. Remove the two reverse idler shaft support bolts.

    8. Object Number: 4842 Size: SH
  8. Remove the transmission housing vent.

    9. Do not remove the metal tube from the housing.


    Object Number: 4778 Size: SH
  9. Remove the backup lamp switch.

    10. Object Number: 6351 Size: SH
  10. Remove the shift shaft block out bushing pin.

    11. Object Number: 4779 Size: SH
  11. Remove the vehicle speed sensor, O-ring, and bolt.

    12. Object Number: 4780 Size: SH
  12. Using the J 36509 and the J 23907 , remove the detent plug, spring, and detent plunger.

    13. Object Number: 4781 Size: SH
  13. If 4WD vehicle, remove the output shaft seal using the J 36825 and the J 23907 . Screw the J 36825 into one of the three perforated holes in the seal.

    14. Object Number: 4782 Size: SH
  14. Remove the six bolts securing the main drive gear bearing retainer to the front case.

    15. Remove the retainer by screwing two of the removed bolts into the threaded holes in the retainer.


    Object Number: 548183 Size: SH
  15. Remove the main drive gear snap ring.

    16. Object Number: 548129 Size: SH
  16. Remove the bolts securing the front housing to the rear housing.

    17. Object Number: 4785 Size: SH
  17. Drive the two dowel pins into the front housing.

    18. Object Number: 548133 Size: SH
  18. Remove the front housing.

    19. Object Number: 4787 Size: SH
  19. Remove the countershaft front bearing.

    20. Object Number: 4788 Size: SH
  20. Remove the reverse idler shaft support. The idler shaft support will snap out.

    21. Object Number: 4789 Size: SH
  21. Move all of the shift forks forward. Engage the 4th gear, the 2nd gear, and Reverse gear. Retain the shift lever detent plunger and spring.

    22. Object Number: 4790 Size: SH
  22. Remove the shift shaft lever roll pin.
    23. 22.1. Rotate the shift shaft lever finger down.
    22.2. Support the shift shaft end.
    22.3. Drive out the roll pin.
    22.4. Ensure that the roll pin clears the 2nd speed gear.

    Object Number: 4791 Size: SH
  23. Shift all of the gears into neutral.

    24. Object Number: 4792 Size: SH
  24. Engage the 5th speed gear.

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


    Object Number: 4793 Size: SH
  25. Push the shift shaft into the housing.

    26. Object Number: 4794 Size: SH
  26. Remove the shift shaft socket roll pin.
    27. 26.1. Rotate the input shaft until a gap in the 5th speed/reverse speed synchronizer hub is directly under the roll pin.
    26.2. Support the shift shaft end.
    26.3. Using a 5 mm (3/16 in) punch, remove the roll pin.

    The roll pin will fall into the transmission housing.


    Object Number: 4807 Size: SH
  27. Remove the following components:
    28. 27.1. The shift shaft
    27.2. The shift shaft socket
    27.3. The shift shaft lever
    27.4. The shift shaft block out bushing

    Object Number: 4795 Size: SH
  28. Rotate the 3rd/4th speed gear shift fork counterclockwise and remove the 3rd/4th speed gear shift fork from the transmission case.

    29. Object Number: 4796 Size: SH
  29. If rear wheel drive (RWD) vehicle loosen the three bolts on the rear of the housing. Do not remove the bolts.

    30. Object Number: 4805 Size: SH
  30. Install the J 36515-15 on the input shaft.
  31. Install the J 36515-16 on the countershaft.
  32. Install the transmission to the J 36515 .
  33. Remove the transmission holding fixture from the transmission.

    34. Object Number: 4797 Size: SH
  34. If RWD vehicle remove the three bolts on the rear of the housing.

    35. Object Number: 7910 Size: SH
  35. If 4WD vehicle, remove the main shaft rear bearing snap ring.

    36. Object Number: 4799 Size: SH
  36. Remove the rear housing (4WD shown). Tap the rear housing with a rubber mallet.

    37. Object Number: 4800 Size: SH
  37. If RWD vehicle, remove the main shaft bearing retainer.

    38. Object Number: 4801 Size: SH
  38. Remove the following components from the mainshaft assembly:
    39. • The two shift forks (1)
    • The reverse idler gear (2)
    • The countershaft rear bearing (4)
    • The countershaft (3)

    Object Number: 4802 Size: SH
  39. If RWD vehicle, using the J 21427-A and the J 24420-B , remove the speed sensor reluctor wheel from the rear of the main shaft.

    40. Do not reuse the reluctor wheel after removal.


    Object Number: 4803 Size: SH
  40. If RWD vehicle, remove the mainshaft rear bearing snap ring (1) and the mainshaft rear bearing (2).

    41. Object Number: 4804 Size: SH
  41. Remove the mainshaft assembly from the J 36515 .

    42. Important: Leave the synchronizer ring on the 3rd/4th synchronizer assembly to prevent the synchronizer detent balls from popping out.

  42. Remove the main drive gear and the main drive gear pilot bearing from the main shaft.

    43. Object Number: 4808 Size: SH
  43. Remove the mainshaft snap ring.

    44. Object Number: 4810 Size: SH
  44. Scribe an alignment mark on the synchronizer hub and the synchronizer sleeve in order to properly reassemble the synchronizer hub assembly.

    45. Object Number: 38500 Size: SH

    Important: When removing the synchronizer hubs use the J 22912-B under the gear for that synchronizer and not the synchronizer sleeve. Do not separate the synchronizer hub from the synchronizer sleeves. Leave the synchronizer rings with the synchronize assembly to prevent the synchronizer detent balls from popping out.

  45. Using a hydraulic press and the J 22912-B remove the 3rd/4th speed gear synchronizer hub assembly, the third speed gear and the synchronizer rings.
  46. Remove the synchronizer assembly from the third gear.

    47. Object Number: 4745 Size: SH
  47. Remove the 3rd speed gear needle bearing assembly (1).

    48. Object Number: 4812 Size: SH
  48. Remove the following components:
    49. 48.1. The 2nd speed gear two piece thrust washer
    48.2. The retainer ring

    Object Number: 4743 Size: SH
  49. Remove the following components:
    50. 49.1. The 2nd speed gear
    49.2. The 2nd speed gear needle bearing assembly

    Object Number: 7907 Size: SH
  50. Remove the 2nd gear synchronizer snap ring from the main shaft.

    51. Object Number: 4815 Size: SH
  51. Remove the following components for the 2nd gear synchronizer:
    52. 51.1. The synchronizer cone
    51.2. The blocker ring
    51.3. The reaction cone
    51.4. The interim ring

    Object Number: 626287 Size: SH
  52. Scribe an alignment mark on the synchronizer hub and the synchronizer sleeve in order to properly reassemble the synchronizer hub assembly.

    53. Important: When removing the synchronizer hubs use the J 22912-B under the gear for that synchronizer and not the synchronizer sleeve. Do not separate the synchronizer hub from the synchronizer sleeves. Leave the synchronizer rings with the synchronize assembly to prevent the synchronizer detent balls from popping out.

  53. Using a hydraulic press and the J 22912-B remove the 1st/2nd speed gear synchronizer hub and the 1st speed gear.

    54. Object Number: 4740 Size: SH
  54. Remove the following components:
    55. 54.1. The synchronizer cone (5)
    54.2. The blocker ring (4)
    54.3. The reactor cone (3)
    54.4. The synchronizer interim ring (2)
    54.5. The 1st speed gear (1)

    Object Number: 4811 Size: SH
  55. Remove the 1st speed gear needle bearing assembly

    56. Object Number: 4739 Size: SH
  56. Turn the mainshaft over to work on the output end.
  57. Remove the following components:
    58. 57.1. The 5th speed gear (3)
    57.2. The 5th speed gear needle bearing assembly (1)

    Object Number: 7906 Size: SH
  58. Remove the snap ring for the 5th gear synchronizer hub from the mainshaft.

    59. Object Number: 626289 Size: SH
  59. Scribe an alignment mark on the synchronizer hub and the synchronizer sleeve in order to properly reassemble the synchronizer hub assembly.

    60. Important: When removing the synchronizer hubs use the J 22912-B under the gear for that synchronizer and not the synchronizer sleeve. Do not separate the synchronizer hub from the synchronizer sleeves. Leave the synchronizer rings with the synchronize assembly to prevent the synchronizer detent balls from popping out.

  60. Using a hydraulic press and the J 22912-B remove the 5th/Reverse speed gear synchronizer assembly and the reverse speed gear.

    61. Object Number: 4735 Size: SH
  61. Remove the following reverse speed gear needle bearing assembly.

    62. Object Number: 626291 Size: SH
  62. Remove the reverse speed gear drag seal.
  63. Remove the 5th speed gear drag seal.

Synchronizer Disassembly

    Object Number: 4732 Size: SH

    Important: Do not mix the synchronizer parts.

  1. Remove the synchronizer rings from the synchronizer assembly.
  2. In order to prevent the loss of the synchronizer detent balls wrap the synchronizer sleeve and hub in a shop rag. Carefully slide the synchronizer hub from the sleeve.
  3. Remove the synchronizer detent balls, springs, and keys from the hub.

Front and Rear Housing Disassembly

    Object Number: 100954 Size: SH
  1. Remove the seal from the main drive gear bearing retainer. Pry the seal out with a small pry bar or the equivalent.

    2. Object Number: 4849 Size: SH
  2. If RWD vehicle, using J 26941 and J 23907 , remove the slip yoke seal.

    3. Object Number: 4847 Size: SH
  3. If 4WD vehicle remove the bolts and the main shaft rear bearing retainer from the rear housing.

    4. Object Number: 4848 Size: SH
  4. If 4WD vehicle use a brass drift to remove the main shaft rear bearing from the rear housing.

    5. Object Number: 4845 Size: SH
  5. Using J 23907 , remove the rear housing shift shaft bearing.
    6. • Install the puller legs behind the bearing lip.
    • If the bearing lip breaks off, install the puller legs behind the inside (outer end) of the bearing lip.

    Object Number: 5226 Size: SH
  6. Using J 36800 and J 23907 , remove the shift shaft front housing bushing.

    7. Object Number: 4841 Size: SH

    Important: Discard all bushings removed during this procedure.

  7. Using J 36507 , remove the two detent lever bushings.

    8. Remove one bushing at a time.


    Object Number: 4837 Size: SH
  8. Put the front housing in a hydraulic press with the front of the housing facing down.
  9. Using J 36183 and J 36184 , remove the input shaft bearing.

Reverse Idler Gear Disassembly

    Object Number: 626190 Size: SH
  1. Remove the snap ring (1) on the opposite end of the wave washer (6).
  2. Remove the thrust washer (3).
  3. Remove the locating ball (2).
  4. Remove the reverse idler gear (4).
  5. Remove the bearing assembly (5).
  6. Remove the other locating ball (2).
  7. Remove the other thrust washer (3).
  8. Remove the wave washer (6).
  9. Remove the other snap ring (8).