GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2000 🢒 Sonoma Pickup - 4WD 🢒 Transmission/Transaxle 🢒 Manual Transmission - NV 1500 🢒 Transmission Assemble

Tools Required

    • J 22873 Mainshaft Bushing Installer
    • J 36183 Press Tube
    • J 36184 Press Tube Reducer
    • J 36190 Universal Drive Handle
    • J 36504 Input Shaft Seal Installer
    • J 36511 Oil Plug Hex Bit
    • J 36798 Shift Rail Bushing Staking Tool
    • J 41663 Assembly Pallet
    • J 44339 Reverse Synchronizer Installer
    • J 44340 Bearing Installer

    Important: When installing the front shift shaft bushing into the front housing, ensure the bushing split line is not aligned with the hydrolock in the front housing.


    Object Number: 144199 Size: SH
  1. Using the J 36798 and the J 36190 , install the shift shaft front bushing into the front housing.

    2. Important: When installing the rear shift shaft bushing into the housing bore, ensure the bushing lip faces toward the housing and the bushing is flush with the top of the housing bore.


    Object Number: 144200 Size: SH
  2. Using the J 36190 , install the rear shift shaft bushing into the rear housing.

    3. Object Number: 144192 Size: SH
  3. Install the shift shaft support and retaining ring into the rear housing.

    4. Object Number: 144201 Size: SH

    Important: Prior to installing the slip yoke oil seal, apply petroleum jelly between the lips of the seal.

  4. Using the J 36504 , install the slip yoke oil seal into the rear housing.

    5. Object Number: 144195 Size: SH
  5. Apply teflon pipe sealant GM P/N 12346004 or equivalent to the threads of the oil drain plug.
  6. Using the J 36511 , install the oil drain plug into the rear housing.

    7. Tighten
    Tighten the oil drain plug to 30 N·m (22 lb ft).


    Object Number: 637810 Size: SH

    Important: 

       • Lubricate all components during assembly.
       • Use lubricant Synchromesh Transmission Fluid Friction Modified GM P/N 12377916 or equivalent.
       • Install the synchronizer sleeves with the offset teeth toward the second, third, and fifth gear.
            Sleeves are identified with the following marks:
          - First and second synchronizer assembly: One groove on the outer diameter (OD) of the sleeve goes toward the first gear.
          - Third and fourth synchronizer assembly: Two grooves on the outer diameter (OD) of the sleeve goes toward the third gear
          - Fifth and reverse synchronizer assembly: Two grooves on the outer diameter (OD) of the sleeve goes toward the fifth gear and one groove toward the reverse gear.

  7. Install the reverse gear onto the output end of the mainshaft

    8. Important: The reverse synchronizer blocking ring should have been marked for identification during disassembly. Ensure the reverse blocking ring being installed is the correct blocking ring. The first gear and fifth gear blocking rings look the same, but are not interchangeable with the reverse blocker ring.

  8. Install the reverse gear synchronizer blocking ring.

    9. Object Number: 637465 Size: SH
  9. Using the J 44339 (1), install the fifth reverse synchronizer assembly. Ensure the synchronizer hub is seated completely on the mainshaft.

    10. Object Number: 637811 Size: SH
  10. Install the fifth reverse synchronizer assembly retainer ring.
  11. Install the fifth gear synchronizer blocking ring.
  12. Install the fifth gear.

    13. Object Number: 637776 Size: SH
  13. Using the J 44340 (1), install the output shaft bearing. Ensure the bearing is completely installed on the mainshaft.
  14. Install the output shaft bearing retainer ring to the mainshaft.
  15. Install the speed sensor rotor down the mainshaft five centimeters (two inches) from the ball bearing.
  16. Using the J 22873 , install the speed sensor rotor.

    17. Object Number: 529475 Size: SH
  17. Using the J 22873 , install the first gear onto the input end of the mainshaft.
  18. Install the first gear synchronizer inner cone.
  19. Install the first gear synchronizer middle cone.
  20. Install the first gear synchronizer blocking rings

    21. Important: Ensure the scribed hub is correctly aligned.

  21. Install the first and second gear synchronizer assembly.

    22. Align the synchronizer rings with the keys on the first and second gear synchronizer. One synchronizer ring should be on each side of the synchronizer assembly.

  22. Install the synchronizer assembly retainer ring.

    23. Ensure the retainer ring is installed into the retainer ring slot around the mainshaft.


    Object Number: 144179 Size: SH
  23. Install the second gear synchronizer blocking ring.
  24. Install the second gear synchronizer middle cone.
  25. Install the second gear synchronizer inner cone.
  26. Install the second gear.

    27. Object Number: 529492 Size: SH
  27. Install the two piece split washer, pin, and the retainer ring.

    28. Object Number: 144172 Size: SH
  28. Install the third gear.
  29. Install the third gear synchronizer blocking ring.
  30. Using the J 22873 install the third and fourth gear synchronizer.
  31. Install the fourth gear synchronizer blocking ring.
  32. Align the synchronizer blocking rings with the keys on the third and fourth gear synchronizer.
  33. Install the retainer ring.

    34. Object Number: 143341 Size: SH
  34. Install the following components onto the input end of the mainshaft:
    35. 34.1. The pocket bearing
    34.2. The input shaft

    Object Number: 144189 Size: SH

    Important: 

       • When assembling the reverse idler gear, ensure the chamfer on the segment and the collar are facing up, toward the rear, with the collar on the top.
       • Ensure the groove on the idler gear is toward the collar.

  35. Install the following components onto the reverse idler shaft:
    36. 35.1. The segment
    35.2. The two O-rings
    35.3. The caged roller bearings
    35.4. The reverse idler gear
    35.5. The idler shaft support collar

    Object Number: 144206 Size: SH
  36. Install the assembled mainshaft onto the J 41663 .
  37. Press the countershaft rear ball bearing onto the countershaft.
  38. Install the snap ring on to the countershaft.
  39. Install the countershaft onto the J 41663 .
  40. Install the reverse idler shaft assembly onto the J 41663 .

    41. Object Number: 144202 Size: SH
  41. Install the output shaft bearing retainer onto the mainshaft and the countershaft.
    42. • Ensure the output shaft bearing retainer is installed behind the ball bearings on the mainshaft and the countershaft.
    • Ensure the fork end of the output shaft bearing retainer is installed under the countershaft ball bearing.
    • Ensure the hook end of the output shaft bearing retainer is installed under the mainshaft ball bearing.

    Object Number: 144206 Size: SH
  42. Install the fifth/reverse shift fork onto the first/second shift fork.
  43. Install the fork assemblies onto the first/second and fifth/reverse gear sleeves.
  44. Install the rear housing over the mainshaft, countershaft and reverse idler shaft assembly.

    45. Object Number: 143298 Size: SH

    Important: Two bolts of different length are used to secure the idler shaft segment to the rear housing. The forward (front) reverse idler shaft assembly hole houses the short bolt.

  45. Install the two bolts that secure the reverse idler shaft assembly to the rear housing.

    46. Finger tighten the two bolts.

    Important: Use new O-rings with the five output shaft bearing retainer to housing bolts.

  46. Install the NEW O-rings on the five output shaft to bearing retainer bolts.

    47. Object Number: 144203 Size: SH

    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.

  47. Install the five output shaft bearing bolts using the following sequence:
    48. 47.1. Finger start bolts 1, 2, and 4.
    47.2. Finger start bolts 3 and 5.
    47.3. Finger tighten the bolts in the following order:

    1, 2, 3, 4, 5.

    47.4. Tighten the five output shaft bearing retainer to housing bolts in the following order:

    1, 2, 3, 4, 5.

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

    47.5. Re-tighten the five output shaft bearing retainer to housing bolts in the following order:

    1, 2, 3, 4, 5.

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

  48. Tighten the reverse idler shaft assembly to housing bolts.

    49. Tighten

    1. Tighten the reverse idler shaft assembly to housing rear bolt to 22 N·m (16 lb ft).
    2. Tighten the reverse idler shaft assembly to housing forward bolt to 44 N·m (33 lb ft).
  49. Remove the rear housing assembly from the J 41663 .

    50. Place the rear housing assembly horizontally.


    Object Number: 143332 Size: SH
  50. Install the third/fourth fork onto the third and fourth gear synchronizer sleeve.

    51. Important: Ensure the shift lever and block- out bushing are positioned correctly on the shift shaft.

  51. Install the shift lever and block-out bushing onto the shift shaft.
  52. install the shift shaft through the first-second shift fork and fifth and reverse shift fork.
  53. Install the shift socket onto the shift shaft.
  54. Slide the shift shaft into the case.
  55. Install the roll pin into the shift lever.
    56. • Rotate the shift shaft and shift lever/blockout bushing assembly until the roll pin holes are aligned and horizontal.
    • Support the shift shaft during installation of the roll pin.
    • Install the roll pin flush with the shift lever.
  56. Install the spring and ball plunger into the hole in the shift lever.
    57. • Rotate the shift shaft counter-clockwise until the shift lever is almost into the fifth-reverse insert notch.
    • Install the spring and plunger into the shift lever.
    • Rotate the shift shaft until the shift lever aligns with the 3-4 insert.

    Object Number: 143327 Size: SH
  57. Install the 22 mm (0.866 in) shift shaft lever roll pin into the shift shaft lever.

    58. Ensure the roll pin to set flush with the shift shaft lever assembly.

  58. Install the shift shaft socket and the 30 mm (1.18 in) roll pin onto the shift shaft.

    59. Ensure the shift shaft socket roll pin is flush with the shift shaft socket hole.


    Object Number: 143314 Size: SH
  59. Install the shift shaft spring and plunger assembly into the shift shaft lever assembly.

    60. Important: The transmission must be in the 3rd or 4th gear install during the installation of the shift tower.

    After the shift tower has been installed to the transmission, the shifter can be engaged into other shift installs.

  60. Install the transmission into the third gear:
    61. 60.1. Center the shift shaft.
    60.2. Push the shift shaft all the way to the rear of the rear housing.
  61. Apply a thin layer of RTV sealer GM P/N 1052942 to the mating surfaces of the rear housing.
  62. Using the J 36183 and the J 36184 , install the input shaft ball bearing into the front housing.
  63. Install the front countershaft roller bearing into the front housing.

    64. Ensure the small end of the countershaft bearing is toward the front housing.


    Object Number: 143323 Size: SH
  64. Install the front housing onto the rear housing.

    65. Object Number: 144205 Size: SH
  65. Install the shift shaft detent blockout bushing pin into the top of the front housing.

    66. Install the shift shaft detent blockout bushing pin by hand in order to ensure the detent lock pin installs into the shift shaft lever and the shift shaft bushing.


    Object Number: 143323 Size: SH
  66. Install the nine bolts securing the front housing to the rear housing.

    67. Tighten

        • Tighten the nine housing bolts to 33 N·m (24 lb ft).
        • Tighten the shift shaft detent blockout bushing pin to 33 N·m (24 lb ft).

    Object Number: 144204 Size: SH
  67. Install the following components:
    68. • The shift shaft detent plunger (1)
    • The spring (2)
    • The detent plug (3)

    Object Number: 143320 Size: SH
  68. Install the snap ring on the input shaft front ball bearing.
  69. Apply a thin layer of RTV sealer GM P/N 12345739 or equivalent to the mating surfaces of the input shaft bearing retainer.

    70. Install the input shaft bearing retainer to the front housing.

  70. Install the five bolts that secure the input shaft bearing retainer to the front housing.

    71. Tighten
    Tighten the bolts that secure the input bearing retainer to 29 N·m (21 lb ft).

  71. Install the backup light switch into the rear housing.

    72. Tighten
    Tighten the backup light switch to 37 N·m (28 lb ft).

  72. Install the speed sensor.

    73. Tighten
    Tighten the speed sensor to 17 N·m (12 lb ft).

  73. In order to prevent spillage, fill the transmission with oil after installing. Refer to Lubrication Specifications .

    74. Object Number: 144191 Size: SH
  74. Using the J 36511 , install the oil fill plug into the rear housing.

    75. Tighten
    Tighten the oil fill plug to 30 N·m (22 lb ft).