Tools Required

J 36850 Transjel® Transmission Assembly Lube

1. Lubricate all components as assembly progresses. Use J 36850 or the equivalent.



2. Install the selective shims. Refer to the Input Shaft, Mainshaft, and Countershaft in Shimming Procedures .



3. Install the following parts:

•	The input shaft bearing race

•	The countershaft bearing race




4. Install the following parts:

4.1.	The input shaft

4.2.	The 4TH speed gear blocking ring




5. Assemble the shift shaft to the mainshaft.

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.

Tools Required

J 36850 Transjel® Transmission Assembly Lube

1. Lubricate all components as the assembly progresses. Use J 36850 or the equivalent.



2. Apply sealant at the transmission case to adapter plate mating surface. Use GM P/N 12345739 or the equivalent.



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



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

4.1.	Shift the transmission into NEUTRAL in order to keep the 3RD/4TH shift shaft from engaging.

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

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




5. Apply anaerobic threadlocker to the threads of the shift lever guide bolts. Use GM P/N 12345382 or the equivalent.



6. 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.
7. Install the shift lever guide bolts.

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

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.




8. Install the adapter plate to transmission case bolts.

Tighten
Tighten the bolts to 35 N·m (26 Ib ft).




9. Install the front offset lever roll pin.
10. Install the roll pin (182). Refer to

    Shift Shaft and Clutch Housing

    
    
    



11. Apply anaerobic threadlocker to the threads of the shift detent assembly. Use GM P/N 12345382 or the equivalent.



12. Install the shift detent assembly.

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




13. Apply sealant to the mating surface of the cover plate. Use GM P/N 12345739 or the equivalent.



14. Install the cover plate and the cover plate bolts.

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




15. 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

J 39441 Gear Installer

Install the 5TH/6TH speed driven gear using the J 39441 . The smaller 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.

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

Tools Required

J 39441 Gear Installer

1. Install the speedometer gear retainer ring.



2. Install the speedometer gear. Use the J 39441 .



3. Install the speedometer retaining ring.



4. Install the sealing ring.

1. Install the following parts:

1.1.	The funnel

1.2.	The selective shims. Refer to the Countershaft Extension in Shimming Procedures .

1.3.	The countershaft extension bearing race




2. Install the following parts:

2.1.	The reverse idler shaft

2.2.	The thrust washer

2.3.	The roller bearing

2.4.	The reverse idler gear

2.5.	The reverse idler gear thrust washer




3. Apply thread sealer to the reverse idler shaft brackets bolt threads. Use GM P/N 12345382 or the equivalent.



4. Install the following parts:

4.1.	The reverse idler shaft bracket

4.2.	The reverse idler shaft bracket bolts

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

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



6. Apply thread sealer to the extension housing bolt threads. Use GM P/N 12346004 or the equivalent.



7. Install the extension housing. Align the 5TH/6TH and reverse shift shaft with the extension housing bore.
8. Install the extension housing bolts and the transmission bumper.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).




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



10. Install the rear offset shift lever roll pin.

1. Apply sealant at extension housing to the shifter mating surface. Use GM P/N 12345739 or the equivalent.



2. Install the shifter and the shifter bolts.

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

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.

3. Remove the transmission from the support fixture.



4. Apply sealant to the threads of the clutch fork pivot lever bolt. Use GM P/N 12345382 or the equivalent.



5. Install the following parts:

5.1.	The clutch fork pivot lever

5.2.	The clutch fork pivot lever nut

5.3.	The clutch fork bolt. Apply thread sealer to the clutch fork bolt. Use GM P/N 12345382.

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




6. Install the clutch housing and the clutch housing bolts.

Tighten
Tighten the bolts to 35 N·m (26 Ib ft).




7. Install the vent tube.

Tools Required

J 36850 Transjel® Lubricant Assembly Lube

1. Lubricate all components as assembly progresses, using J 36850 .



2. Install the input shaft in the adapter plate.



3. Assemble the shift shaft to the mainshaft.
4. Install the neutral return roll pin to the shift shaft.
5. Install the mainshaft and the shift shaft assembly into the adapter plate.



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. Use J 36850 or the equivalent.

1. Apply sealant GM P/N United States 12345739, GM P/N Canada 10953472 or 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 threadlock GM P/N United States 12346004, GM P/N Canada 10953480 or 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 detent assembly to 40 N·m (30 Ib ft).




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



11. Install the transmission case cover and the case cover bolts.

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




12. Install the reverse lockout body and bolt in the cover plate.

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




13. Install the reverse lockout solenoid to reverse lockout body assembly, using the J 41099 .

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




14. 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 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.

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

Tools Required

J 44395 Transmission Support Fixture

1. Install the following parts in order:

1.1.	The funnel

1.2.	The selective shims. Refer to the Countershaft Extension in Shimming Procedures.

1.3.	The countershaft extension bearing race




2. Install the following parts in order:

2.1.	The reverse idler shaft

2.2.	The roller bearing

2.3.	The reverse idler gear




3. 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.

4. Install the following parts in order:

4.1.	The reverse idler shaft bracket.

4.2.	The reverse idler shaft bracket bolts.

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




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



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




Important: Align the 5th/6th shift shaft to the extension housing bore in order to install the extension housing.

7. Install the extension housing.
8. Install the extension housing bolts.

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

9. Install the vent tube.



10. Remove the J 44395 .



11. Install the remaining two adapter plate bolts (1) and (2).

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