Special Tools

1. Install the shift rod and bushing.



2. Install the intermediate shaft needle bearing to the transmission housing using the J 44383 bearing installer  (1) and the J 8092 driver handle  (2).



3. Install a new shifter shaft bearing flush with the casting in the transmission housing, using the J 44381 bearing remover  (1) and the J 8092 driver handle  (2).




Note: Do not over apply the threadlocker to the bolt threads.

4. Apply GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the reverse lockout lever bolt threads.

Caution: Refer to Fastener Caution in the Preface section.

Note: The spring (2) fingers must be positioned on either side of the lever (3).

5. Install the reverse lockout lever (3), spring (2), and the bolt (1) to the transmission housing, if equipped and tighten the bolt to 6 N·m (53 lb in).



6. Install a new differential bearing race to the transmission housing using the J 44385 seal installer  (2) and the J 7079-2 driver handle  (1).



7. Install a new differential side bearing race seal to the transmission housing using the J 44385 seal installer  (2) and the J 7079-2 driver handle  (1).



8. Install the countershaft bearing to the clutch housing using the J 44381 bearing remover  (1) and the J 7079-2 driver handle  (2).
9. Install a new snap ring.



10. Install the input shaft bearing to the clutch housing using the J 44381 bearing remover  (2) and the J 7079-2 driver handle  (1).



11. Install the output shaft bearing race and bolts using the J 44387-1 (2), J 44387-2 (3), and the J 7079-2 driver handle  (1) and tighten the output shaft bearing bolts to 10 N·m (89 lb in).



12. Install a new differential bearing race to the clutch housing using the J 44385 seal installer  (2) and the J 7079-2 driver handle  (1).




Note: If either the case or shifter detent is damaged, it may be necessary to install a new shifter detent and/or case.

13. Install the shifter detent into the case if necessary.



14. Install a new differential output shaft seal to the clutch housing using the J 44385 seal installer  (2) and the J 8092 driver handle  (1).



15. Install the snap rings to the input shaft and output shaft bearings.
16. Install the input shaft and output shaft bearings into the transmission housing using the J 44385 seal installer  (2) and the J 7079-2 driver handle  (1).



17. Install the shift forks and the input shaft and output shaft onto the J 44375 assembly pallet .



18. Install the countershaft and the shift fork onto the J 44375 assembly pallet .
19. Rotate the shaft to verify all gears are properly meshing.



20. Install the housing onto the shift forks and the shafts on to the J 44375 assembly pallet . Line up the shift forks and the shafts with the housing.




Note: 

Install the transaxle case to the shafts evenly using the J 44376 pusher/puller .
21. Install the transaxle case to the shafts using the J 44376 pusher/puller .



22. Shift the transmission into 4th and 5th gear using a screwdriver in an upward direction.
23. Apply GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the input and output shaft bolts.
24. Install NEW input and output shaft bolts while holding the transmission into 4th and 5th gear in an upward direction and tighten the shaft bolts to 110 N·m (81 lb ft).




Note: If shimming is required, refer to Shimming Procedures before installing the cover.

25. Install sealant GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the rear cover.




Note: The oil guide only installs in one direction. Ensure the oil guide is completely seated in the gear shafts.

26. Install the oil guide.
27. Install the rear cover.
28. Install the rear cover bolt and tighten to 25 N·m (18 lb ft).



29. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the backup lamp switch.
30. Install the backup lamp switch into the transaxle case and tighten to 18 N·m (13 lb ft).



31. Turn the transaxle case and the J 44375 assembly pallet over on the table.
32. Remove the J 44375 assembly pallet from the gear shafts and the shift forks.



33. Install the oil tube into the transaxle case.



34. Install the shift rod to the shift fork.




Note: Use only the approved sealer for the transaxle case to shifter cover mating surface.

35. Apply sealer GM P/N 12378516 (Canadian P/N 88900757) or equivalent to the transaxle case to shifter cover mating surface.



36. Install the shifter and the shifter retaining bolts and tighten to 25 N·m (18 lb ft).

Install all possible shifter bolts with the shifter in the neutral position. Install the last shifter bolt in gear and then shift the transmission back into neutral.




37. Shift the transmission into neutral.
38. Apply GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the shifter guide bolt.

Caution: Hand start and tighten the shifter guide bolt to avoid damaging the shift lever.

39. Install the shifter guide bolt and tighten to 25 N·m (18 lb ft).



40. Install the differential into the transaxle case.




Note: The step in the roller bearing faces opposite of the pinion gear.

41. Install the roller bearing onto the output shaft.



42. Install the magnet into the transaxle case.



43. Apply sealant GM P/N 12378516 (Canadian P/N 88900757) or equivalent to the transaxle case to clutch housing mating surface.



44. Install the clutch housing to the transaxle case.



45. Install the countershaft into the clutch housing bearing using the J 44389 bearing installer .



46. Install the clutch housing to transaxle case bolts and tighten the housing bolts to 27 N·m (20 lb ft).



47. Turn the transmission over.
48. Install the transaxle case to clutch housing bolts and tighten the housing bolts to 27 N·m (20 lb ft).



49. Turn the transmission so the shifter is on top.
50. Shift the transmission into any gear.



51. Install the actuator and tube.
52. Install the actuator and tube bolts and tighten to 10 N·m (89 lb in).



53. Apply GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the transmission drain plug.
54. Install the transmission drain plug and tighten to 38 N·m (28 lb ft).



55. Install the transmission fill cap.



56. Hold the input shaft with the J 44377 tool .
57. Apply GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the intermediate shaft bolt.
58. Install the bolt in the intermediate shaft and tighten to 95 N·m (70 lb ft).



59. Install a new plastic oil guide into the intermediate shaft.




Note: Ensure not to press the sealing cap past the bottom of the chamfer.

60. Install a new intermediate shaft sealing cap.



61. Apply GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the vehicle speed sensor bolt.
62. Install the vehicle speed sensor, seal, and bolt and tighten the bolt to 12 N·m (8 lb ft).



63. Install the shift cable bracket (4), the isolators (3), the spacers (2) and the bolt (1) and tighten the shift cable bracket bolt to 20 N·m (15 lb ft).