| Subject: | Manual Transmission Disassemble -- 5th Gear Damage During Removal |
| Models: | 2008-2009 Chevrolet Corvette |
| with Manual Transmission (RPOs MM6, MZ6 or MH3) |
Dealerships report that some technicians have experienced 5th gear damage during removal using the specified service tools.
Investigative inquiries have identified two causes which are contributors to the 5th gear damage:
| • | Inadvertent attempts to remove the 5th speed gear while the two-piece thrust washer and locking ring are still in place. |
| • | When utilizing the special puller setup (J 8433, J 39431, J 39431-2), the puller (J 39431) may not be installed level. This unlevel condition allows for only one of the tool's feet to contact the gear. This results in excessive loads being
induced into the gear, thus fracturing the gear teeth when the gear is drawn from the main shaft. The use of air-powered impact tools will make this condition worse by quickly loading the gear. |
When servicing the Corvette manual transmission, be sure to follow the Transmission Disassemble procedures in SI which details the proper disassemble sequence. Also ensure the proper installation and leveling of the special tool needed for 5th gear removal.
Make sure that both puller (J 39431) feet are in contact with the lower gear surface prior to drawing the gear from the shaft.
