MANUAL TRANS SERVICE INFORMATION

REVISED MANUAL TRANSMISSION SERVICE PROCEDURES-1981-1982 LIGHT DUTY C-K TRUCK MODELS EQUIPPED WITH 4-SPEED 117MM TRANSMISSION ON VEHICLE SERVICE REMOVAL (EXCEPT K SERIES) 1.REMOVE ATTACHING SCREWS FROM TRANSMISSION SHIFT LEVER BOOT RETAINER. SLIDE BOOT AND RETAINER UP LEVER AND REMOVE TRANSMISSION SHIFT LEVER. TO REMOVE SHIFT LEVER, PUSH DOWN ON COLLAR AND TURN COUNTER-CLOCKWISE. 2.RAISE VEHICLE AND SUPPORT ENGINE WITH A SUITABLE FLOOR STAND. 3.DRAIN TRANSMISSION AND DISCONNECT THE SPEEDOMETER CABLE FROM TRANSMISSION. 4.DISCONNECT PROPELLER SHAFT FRONT U-JOINT AT TRANSMISSION YOKE, AND TIE UP OUT OF WAY. 5.DISCONNECT EXHAUST PIPES AT EXHAUST MANIFOLDS. 6.REMOVE TRANSMISSION MOUNT-TO-CROSSMEMBER BOLTS. 7.SUPPORT TRANSMISSION WITH A SUITABLE FLOOR STAND. REMOVE FRAME TO CROSSMEMBER BOLTS AND REMOVE CROSSMEMBER FROM VEHICLE. 8.REMOVE TRANSMISSION-TO-CLUTCH HOUSING ATTACHING BOLTS. REMOVE UPPER BOLTS FIRST AND INSTALL TRANSMISSION GUIDE PINS J-1126. USE OF THE GUIDE PINS WILL PREVENT DAMAGE TO THE CLUTCH ASSEMBLY. 9.SLIDE TRANSMISSION REARWARD UNTIL MAIN DRIVE GEAR CLEARS THE CLUTCH ASSEMBLY AND LOWER ASSEMBLY FROM VEHICLE. 10.IF DESIRED, A CAREFUL CHECK OF CLUTCH COMPONENTS SHOULD BE MADE AFTER THE TRANSMISSION HAS BEEN REMOVED. IF THE CLUTCH REQUIRES REPAIR, REFER TO SECTION 7C BEFORE TRANMISSION IN REINSTALLED IN THE VEHICLE. INSTALLATION 1.APPLY A LIGHT COATING OF HIGH TEMPERATURE GREASE TO THE MAIN DRIVE GEAR RETAINER AND SPLINED PORTION OF TRANSMISSION MAIN DRIVE GEAR SHAFT TO ASSURE FREE MOVEMENT OF CLUTCH AND TRANSMISSION COMPONENTS DURING ASSEMBLY. NOTICE: DO NOT APPLY AN EXCESSIVE AMOUNT OF GREASE IN THE ABOVE AREAS, AS UNDER NORMAL OPERATION THIS GREASE COULD BE THROWN ONTO CLUTCH FACING RESULTING IN CLUTCH PROBLEMS. 2.POSITION TRANSMISSION TO THE CLUTCH HOUSING AND INSTALL ATTACHING BOLTS. TORQUE BOLTS TO SPECIFICATION. 3.POSITION FRAME CROSSMEMBER AND INSTALL RETAINING BOLTS. INSTALL TRANSMISSION MOUNT-TO-CROSSMEMBER BOLTS. TORQUE BOLTS TO SPECIFICATIONS. 4.CONNECT PROPELLER SHAFT AT TRANSMISSION AND TORQUE BOLTS TO SPECIFICATION. 5.CONNECT SPEEDOMETER CABLE. 6.CONNECT EXHAUST PIPES TO EXHAUST MANIFOLDS. 7.FILL TRANSMISSION WITH LUBRICANT SPECIFIED IN SECTION OB. 8.REMOVE SUPPORTS AND LOWER VEHICLE. 9.INSTALL TRANSMISSION SHIFT LEVER, BOOT, RETAINER AND ATTACHING SCREWS. REMOVAL (K SERIES) 1.REMOVE ATTACHING SCREWS FROM TRANSMISSION SHIFT LEVER BOOT RETAINER. SLIDE BOOT AND RETAINER UP LEVER AND REMOVE TRANSMISSION SHIFT LEVER. TO REMOVE SHIFT LEVER, PUSH DOWN ON COLLAR AND TURN COUNTER-CLOCKWISE. 2.RAISE VEHICLE AND SUPPORT ENGINE WITH A SUITABLE FLOOR STAND. DRAIN TRANSFER CASE AND TRANSMISSION. 3.DISCONNECT SPEEDOMETER CABLE. 4.DISCONNECT PROPELLER SHAFTS AT TRANSFER CASE AND TIE UP, AWAY FROM WORK AREA. 5.SUPPORT TRANSFER CASE IN A SUITABLE CRADLE. REMOVE BOLTS ATTACHING TRANSFER CASE TO ADAPTER, AND REMOVE TRANSFER CASE. REFER TO SECTION 7E. 6.DISCONNECT EXHAUST PIPES AT EXHAUST MANIFOLDS. 7.REMOVE TRANSMISSION MOUNT-TO-CROSSMEMBER BOLTS. 8.SUPPORT TRANSMISSION AND REMOVE FRAME TO CROSSMEMBER BOLTS. ROTATE CROSSMEMBER TO CLEAR FRAME RAILS AND REMOVE FROM VEHICLE. 9.REMOVE TRANSMISSION-TO-CLUTCH HOUSING ATTACHING BOLTS. REMOVE UPPER BOLTS FIRST AND INSTALL TRANSMISSION GUIDE PINS J-1126. USE OF THE GUIDE PINS WILL PREVENT DAMAGE TO THE CLUTCH ASSEMBLY. 10.SLIDE TRANSMISSION REARWARD UNTIL MAIN DRIVE GEAR CLEARS THE CLUTCH ASSEMBLY AND LOWER ASSEMBLY FROM VEHICLE. 11.IF DESIRED, A CAREFUL CHECK OF CLUTCH COMPONENTS SHOULD BE MADE AFTER THE TRANSMISSION HAS BEEN REMOVED. IF THE CLUTCH REQUIRES REPAIR, REFER TO SECTION 7C BEFORE TRANSMISSION IS REINSTALLED IN THE VEHICLE. INSTALLATION 1.APPLY A LIGHT COATING OF HIGH TEMPERATURE GREASE TO THE MAIN DRIVE GEAR BEARING RETAINER AND SPLINED PORTION OF TRANSMISSION MAIN DRIVE GEAR SHAFT TO ASSURE FREE MOVEMENT OF CLUTCH AND TRANSMISSION OF CLUTCH AND TRANSMISSION COMPONENTS DURING ASSEMBLY. NOTICE: DO NOT APPLY AN EXCESSIVE AMOUNT OF GREASE IN THE ABOVE AREAS, AS UNDER NORMAL OPERATION THIS GREASE COULD BE THROWN ONTO CLUTCH FACINGS RESULTING IN CLUTCH PROBLEMS. 2.POSITION TRANSMISSION-TO-CLUTCH HOUSING. INSTALL BOLTS ATTACHING TRANSMISSION TO CLUTCH HOUSING AND TORQUE TO SPECIFICATIONS. 3.POSITION CROSSMEMBER AND INSTALL ATTACHING BOLTS. INSTALL TRANSMISSION MOUNT TO CROSSMEMBER BOLTS. TORQUE BOLTS TO SPECIFICATIONS. 4.POSITION TRANSFER CASE TO ADAPTER AND INSTALL ATTACHING BOLTS. TORQUE BOLTS TO SPECIFICATIONS. 5.CONNECT PROPELLER SHAFTS TO TRANSFER CASE. TORQUE BOLTS TO SPECIFICATIONS. 6.CONNECT SPEEDOMETER CABLE. 7.CONNECT EXHAUST PIPES TO EXHAUST MANIFOLDS. 8.FILL TRANSMISSION AND TRANSFER CASE WITH LUBRICANT RECOMMENDED IN SECTION OB OF THIS MANUAL. 9.REMOVE SUPPORTS AND LOWER VEHICLE. 10.INSTALL TRANSMISSION SHIFT LEVER, BOOTS, RETAINERS AND ATTACHING SCREWS.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.