Tools Required

J 36850 Transjel® Transmission Assembly Lube

1. Lubricate all components as assembly progresses, using the J 36850 .
2. Install the input shaft in the adapter plate.
3. Install the 4th speed gear blocker ring.



4. Assemble the shift shaft to the mainshaft.
5. Install the mainshaft and the shift shaft assembly.



6. Install the countershaft assembly using the following sequence:

6.1.	Lift up the mainshaft assembly enough in order to install the countershaft assembly.

6.2.	Install the countershaft assembly.

6.3.	Lift the mainshaft assembly enough in order to rotate the input shaft to engage the synchronizer keys with 4th gear blocking ring.




7. Install the 5th/6th and the reverse shift shaft.

Align the slots of the shift shaft levers with the interlock plate.

Caution: The reverse lockout assembly is under spring pressure. Exercise caution when removing the retainer ring, as bodily injury may result.

1. Install the reverse lockout plunger (6).
2. Install the reverse lockout outer spring (5).
3. Install the reverse lockout collar (4).
4. Compress the reverse lockout plunger and the collar (4) in a vise and Install the retainer ring (3).
5. Install the reverse lockout inner spring (2).
6. Install the reverse lockout components in the body (1).
7. Install the retainer ring (7).
8. Install the O-ring to body (8).

Tools Required

Important: Lubricate all components as the assembly progresses, using the J 36850 or the equivalent.




1. Apply sealant GM P/N United States 12345739, GM P/N Canada 10953472 or the equivalent, to the transmission case to adapter plate mating surface.



2. Install the ball detent and the spring in the front offset lever.



3. Do the following in order to install the transmission case and the offset lever:

3.1.	Shift the transmission into NEUTRAL in order to keep the 3rd/4th shift shaft from engaging.

3.2.	Install the offset lever.

3.3.	Compress the front offset lever together while sliding it onto the shift shaft. This will prevent the spring release of the inner components.

3.4.	Slide the transmission case onto the gear clusters and the shift rail components.




4. Apply sealant GM P/N United States 12346004, GM P/N Canada 10953480 or the equivalent to the threads of the shift lever guide bolts.




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.

5. Install the shift lever guide bolts and pull up on 5th/6th and reverse shift rail assembly. This will help align the slot of the shift interlock plate with the guide bolt hole.

Tighten
Tighten the bolts to 27 N·m (20 Ib ft).




6. Install the adapter plate to transmission case bolts.

Tighten
Tighten the bolts to 48 N·m (36 Ib ft).




7. Install the magnets into the transmission case.



8. Install the offset lever roll pin.



9. Install the shift detent assembly.

Tighten
Tighten the bolts to 40 N·m (30 Ib ft).




10. Apply sealant GM P/N United States 12345739, GM P/N Canada 10953472 or equivalent to the mating surface of the cover plate.



11. Install the cover plate and the cover plate bolts.

Tighten
Tighten the bolts to 20 N·m (15 Ib ft).




12. Install the computer aided gear select solenoid.

Tighten
Tighten the solenoid to 40 N·m (30 Ib ft).

1. Position the transmission in the horizontal position.
2. Install the countershaft extension assembly and the 5th/6th shift fork. The splines of the countershaft extension must engage the splines of the countershaft.



3. Install the 5th/6th shift fork retainer ring.

Tools Required

Install the 5th/6th speed driven gear using the J 39441 and the J 39441-10 . The smaller outside diameter (OD) of the gear faces down.

1. Install the reverse shift fork, the synchronizer and the thrust washer.



2. Install a new shift fork retainer ring.



3. Install the reverse synchronizer retainer ring.

Tools Required

J 5590 Crankshaft Gear Installer

1. Install the following parts in order:

1.1.	The blocking ring

1.2.	The wave washer

1.3.	The wave washer so the concave side faces the blocking ring

1.4.	The caged needle bearing

1.5.	The reverse speed gear

1.6.	The thrust washer

1.7.	The retainer ring




2. Install the following parts in order:

2.1.	The spacer

2.2.	The roller bearing

2.3.	The spacer

2.4.	The roller bearing retainer ring




3. Install the retainer ring.
4. Install the speed sensor reluctor wheel using J 5590 .
5. Install the retainer ring.

1. Install the funnel.
2. Install the selective shims. Refer to the Countershaft Extension in Shimming Procedures .
3. Install the countershaft extension bearing race.



4. Install the following parts in order:

4.1.	The reverse idler shaft

4.2.	The roller bearing

4.3.	The reverse idler gear




5. Apply Loctite® 272 GM P/N 12345382 or the equivalent to the reverse idler shaft brackets bolt threads.




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.

6. Install the reverse idler shaft bracket.
7. Install the reverse idler shaft bracket bolts.

Tighten
Tighten the bolts to 25 N·m (18 Ib ft).




8. Apply sealant GM P/N 12345739 or equivalent to the extension housing to the transmission case mating surface.



9. Apply thread sealer GM P/N 12346004 or equivalent to the top two extension housing bolts.



10. Install the extension housing.
11. Install the extension housing bolts and the transmission bumper.

Tighten
Tighten the bolts to 48 N·m (36 lb ft).

12. Install the vent tube and bolt (if removed).



13. Install the rear offset shift lever and the isolator cup.



14. Install the rear offset shift lever roll pin.
15. Apply sealant GM P/N 12345739 or the equivalent to the shift lever-to-extension housing mating surface.



16. Install the vehicle speed sensor.
17. Install the vehicle speed sensor bolt.

Tighten
Tighten the bolts to 10 N·m (89 lb in).




18. Install the reverse lockout body and bolt to the extension housing.

Tighten
Tighten the bolts to 18 N·m (13 lb ft).




19. Install the reverse lockout solenoid into the reverse lockout body using the J 41099 .

Tighten
Tighten the bolts to 40 N·m (30 lb ft).





Caution: The correct shifter bolts must be used with the proper shifter. Failure to use the correct shifter bolts may cause shifter to detach from the transmission causing loss of shift control which could result in personal injury.

Notice: The correct shifter bolts must be used with the proper shifter. Failure to use the correct shifter bolts with the proper shifter could cause damage to the transmission extension housing or the shifter to detach from the transmission extension housing.

Important: Pay attention to the different shifters and bolt lengths.

Standard shifter (1) bolt length -- 20 mm (0.80 in).
Optional shifter (2) bolt length -- 25 mm (0.98 in).
20. Install the shifter and shifter bolts.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).