GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2006 🢒 Grand Am 🢒 Transmission/Transaxle 🢒 Manual Transmission - MTN 🢒 Transmission Assemble

    Object Number: 960572 Size: SH
  1. Using a dial indicator, check the output shaft journals for runout. Maximum runout is 0.03 mm (0.0012 in).
  2. If the runout exceeds the maximum, replace the output shaft.

    3. Object Number: 963183 Size: SH
  3. Using a micrometer, measure the outer diameter of the input shaft journal surfaces.

    4. Minimum Outer Diameter

        • 1: 31.985 mm (1.2592 in)
        • 2: 37.985 mm (1.4955 in)
        • 3: 32.985 mm (1.2986 in)
  4. If the out diameter is less than the minimum, replace the output shaft.

    5. Object Number: 963178 Size: SH
  5. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm (0.014 in). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.

    6. Object Number: 963177 Size: SH
  6. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.70 mm (0.0276 in). If the clearance is less than the minimum, replace the synchronizer ring.

    7. Object Number: 963174 Size: SH
  7. Check the 2nd gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.

    8. Object Number: 963172 Size: SH
  8. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm (0.0295 in). If the clearance is less than the minimum, replace the synchronizer ring.

    9. Object Number: 963168 Size: SH
  9. Check the 1st gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.

    10. Object Number: 963166 Size: SH
  10. Using a press, install the front bearing inner race.

    11. Object Number: 963193 Size: SH
  11. Install the snap ring to the output shaft. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 in).

    12. Object Number: 963199 Size: SH
  12. Assemble the reverse gear assembly.

    13. Object Number: 963158 Size: SH
  13. Install the ball to the output shaft.

    14. Object Number: 963155 Size: SH
  14. Install the 1st gear thrust washer to the output shaft.

    15. Object Number: 963149 Size: SH
  15. Apply gear oil to the roller bearing, then install the roller bearing to the output shaft.

    16. Object Number: 963496 Size: SH
  16. Install the No.1 synchronizer to 1st gear.

    17. Object Number: 963499 Size: SH
  17. Place the reverse gear assembly and align the No.1 synchronizer ring slots with the No.1 shifting keys.

    18. Object Number: 963128 Size: SH
  18. Using a press, install the reverse gear assembly, 1st gear and the No.1 synchronizer to the output shaft.

    19. Object Number: 963505 Size: SH
  19. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 in). Install the snap ring to the output shaft.

    20. Object Number: 963510 Size: SH
  20. Install the spacer to the output shaft.

    21. Object Number: 963514 Size: SH
  21. Install the roller bearing to the output shaft.

    22. Object Number: 963518 Size: SH
  22. Place the No.2 synchronizer ring on the 2nd gear.

    23. Object Number: 963537 Size: SH
  23. Install the 2nd gear with the No.2 synchronizer rings and align the No.2 synchronizer ring slots with the No.1 shifting keys.

    24. Object Number: 963582 Size: SH
  24. Using a press, install the 3rd driven gear to the output shaft.

    25. Object Number: 963584 Size: SH
  25. Install the spacer to the output shaft.

    26. Object Number: 963587 Size: SH
  26. Using a press, install the radial ball bearing and the 4th driven gear to the output shaft.

    27. Object Number: 960577 Size: SH
  27. Assemble the No.2 hub sleeve assembly.

    28. Object Number: 960582 Size: SH
  28. Apply gear oil to the roller bearing, then install the roller bearing to the input shaft.

    29. Object Number: 960591 Size: SH
  29. Install the 3rd gear on the input shaft.

    30. Object Number: 960599 Size: SH
  30. Install the No.2 3rd gear synchronizer ring.

    31. Object Number: 960614 Size: SH
  31. Using a press, install the No.2 hub sleeve and 3rd gear to the input shaft.

    32. Object Number: 960704 Size: SH
  32. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 in).
  33. Using a brass bar and hammer, install the No.2 hub sleeve snap ring.

    34. Object Number: 960715 Size: SH
  34. Place the No.2 4th gear synchronizer ring on the No.2 Hub sleeve assembly and align the No.2 synchronizer ring slots with the No.2 shifting keys.

    35. Object Number: 960721 Size: SH
  35. Install the spacer to the input shaft.
  36. Apply gear oil to the roller bearing, then install the roller bearing on the input shaft.

    37. Object Number: 960737 Size: SH
  37. Install 4th gear to the input shaft.

    38. Object Number: 960754 Size: SH
  38. Using a press, install the center ball bearing.

    39. Object Number: 960283 Size: SH
  39. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 in).
  40. Install the input shaft snap ring.

    41. Object Number: 960243 Size: SH
  41. Using a feeler gage, measure the thrust clearance for 4th gear of the input shaft.

    42. Thrust Clearance
    Thrust Clearance: 0.10-0.55 mm (0.0039-0.0217 in).

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 960042 Size: SH
  42. Install the bolt and the transaxle case receiver to the transaxle case.

    43. Tighten
    Tighten the bolt to 11 N·m (8 lb ft).


    Object Number: 960022 Size: SH
  43. Install the bearing lock plate and bolt.

    44. Tighten
    Tighten the bolt to 11 N·m (8 lb ft).


    Object Number: 959981 Size: SH
  44. Using a press, install the output shaft front bearing.

    45. Object Number: 959935 Size: SH
  45. If the output shaft front bearing requires replacement, install the bolt and output shaft cover.

    46. Object Number: 959879 Size: SH
  46. Using a press, install the input shaft bearing.

    47. Object Number: 959891 Size: SH
  47. If the input shaft bearing has been replaced, install a new oil seal.

    48. Oil Seal Installation Depth
    Oil Seal installation depth should be 15.6-16.0 mm (0.614-0.630 in).


    Object Number: 959791 Size: SH
  48. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.89 mm (0.0350 in). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.

    49. Object Number: 959788 Size: SH
  49. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm (0.0295 in). If the clearance is less than the minimum, replace the synchronizer ring.

    50. Object Number: 959775 Size: SH
  50. Check the 5th and 6th gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.

    51. Object Number: 959759 Size: SH
  51. Assemble the No.3 clutch hub assembly.

    52. Object Number: 959753 Size: SH
  52. Install the magnet to the transaxle case

    53. Object Number: 959747 Size: SH
  53. Install the differential case assembly to the transaxle case.

    54. Object Number: 959739 Size: SH
  54. Install the input and output shafts together into the transaxle case.

    55. Object Number: 959734 Size: SH
  55. Install the No.2 gear shift fork to the No.2 hub sleeve groove.

    56. Object Number: 959728 Size: SH
  56. Install the No.3 gear shift fork shaft to the reverse shift fork to the transaxle case.
  57. Install the reverse shift fork.

    58. Object Number: 959693 Size: SH
  58. Install the No.1 gear shift fork to the reverse gear assembly.

    59. Object Number: 959686 Size: SH
  59. Install the No.1 gear shift head to the shift shaft.

    60. Object Number: 959675 Size: SH
  60. Install the No.1 gear shift fork shaft to the No.1 gear shift fork to the transaxle case.

    61. Object Number: 1162528 Size: SH
  61. Install the No.2 gear shift fork shaft to the No.2 gear shift fork.
  62. Install the No.1 gear shift head, No.1 gear shift fork and the reverse shift fork to the transaxle case.

    63. Object Number: 959649 Size: SH
  63. Ensure that the 3 gear shift heads are aligned correctly.

    64. Object Number: 959640 Size: SH
  64. Apply Threadlocker 242 G/M P/N 12345382 to the 3 gear shift fork set bolts.
  65. Install the 3 gear shift fork set bolts.

    66. Tighten
    Tighten the set bolts to 16 N·m (12 lb ft).


    Object Number: 959608 Size: SH
  66. Install the 2 snap rings to the No.1 and No.2 gear shift fork shafts.

    67. Object Number: 959575 Size: SH
  67. Install the reverse idler gear, thrust washer and shaft.

    68. Object Number: 959540 Size: SH
  68. Set the pin on the top of the reverse shift arm into the groove on the reverse idler gear.
  69. Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing.

    70. Object Number: 959477 Size: SH
  70. Install the 2 reverse shift arm bracket, then install the bracket retaining bolts.

    71. Tighten
    Tighten the bolts to 17 N·m (13 lb ft).


    Object Number: 959312 Size: SH
  71. Install the oil receiver pipes to the transaxle case.
  72. Install the oil receiver retaining bolts.

    73. Tighten
    Tighten the bolts to 17 N·m (13 lb ft).


    Object Number: 959278 Size: SH
  73. Apply RTV Silicone Sealer GM  P/N 12346240 (Canadian  P/N 10953493) or equivalent to the transaxle case side.

    74. Object Number: 959264 Size: SH
  74. Install the 13 transaxle case retaining bolts.

    75. Tighten
    Tighten the 13 bolts to 30 N·m (22 lb ft).


    Object Number: 959262 Size: SH
  75. Install the 3 transmission case retaining bolts.

    76. Tighten
    Tighten the 3 bolts to 30 N·m (22 lb ft).


    Object Number: 959157 Size: SH
  76. Using a Allen wrench or equivalent, install the 2 screw plugs to the transaxle case.

    77. Tighten

        • Tighten screw plug (a) to 13 N·m (9 lb ft).
        • Tighten screw plug (b) to 39 N·m (29 lb ft).

    Object Number: 959072 Size: SH
  77. Using a Allen wrench or equivalent, Install the 3 screw plug assemblies to the transaxle case.

    78. Tighten
    Tighten the 3 screw plugs to 24.5 N·m (18 lb ft).


    Object Number: 959007 Size: SH
  78. Install the snap ring to the No.2 shift fork shaft.

    79. Object Number: 958960 Size: SH
  79. Install the reverse idler gear shaft lock bolt and gasket to the transaxle case.

    80. Tighten
    Tighten the lock bolt to 29 N·m (22 lb ft).


    Object Number: 958952 Size: SH
  80. Using snap ring pliers or equivalent, install the 2 snap rings.

    81. Object Number: 958922 Size: SH
  81. Install the rear bearing retainer to the transaxle case.
  82. Coat the 5 rear bearing retainer bolts with Threadlocker 242 G/M  P/N 12345382 or the equivalent.
  83. Install the bolts.

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


    Object Number: 958905 Size: SH
  84. Install the 5th driven gear.

    85. Object Number: 958841 Size: SH
  85. Install the 2 spacers and the roller bearing.

    86. Object Number: 958758 Size: SH
  86. Install the snap ring to the output shaft.

    87. Object Number: 958727 Size: SH
  87. Install 5th gear and the 5th gear synchronizer ring to the input shaft.

    88. Object Number: 958519 Size: SH
  88. Before installing the No.3 clutch hub assembly and input shaft rear ball bearing assembly, place a suitable wooden block on the rear side of the input shaft.

    89. Object Number: 958722 Size: SH
  89. Install the No.3 clutch hub assembly.

    90. Object Number: 956350 Size: SH
  90. Select a snap ring that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.004 in).
  91. Install the 5th gear snap ring to the shaft.

    92. Object Number: 956349 Size: SH
  92. Using a dial indicator, measure the radial runout of 6th gear.

    93. Thrust Clearance
    Standard radial runout should be between 0.015-0.056 mm (0.0006-0.0022 in). Maximum runout should not exceed 0.56 mm (0.0022 in).

  93. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.

    94. Object Number: 956348 Size: SH
  94. Using a dial indicator, measure the thrust clearance of 5th gear.

    95. Thrust Clearance
    Standard thrust clearance should be between 0.10-0.62 mm (0.0039-0.0244 in). Maximum clearance should not exceed 0.62 mm (0.0244 in).


    Object Number: 956342 Size: SH
  95. Install the No.3 gear shift fork and No.3 hub sleeve.
  96. Coat the retaining bolt with Threadlocker 242 G/M P/N 12345382 or the equivalent.
  97. Install the bolt.

    98. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).


    Object Number: 956338 Size: SH
  98. Install the 6th gear synchronizer ring.

    99. Object Number: 956336 Size: SH
  99. Install the roller bearing and spacer to the input shaft.

    100. Object Number: 956332 Size: SH
  100. Install the 6th drive gear, then the rear bearing to the input shaft.

    101. Object Number: 956331 Size: SH
  101. Install the input shaft snap ring.

    102. Object Number: 956329 Size: SH
  102. Install the spacer to the output shaft.

    103. Object Number: 956326 Size: SH
  103. Install the rear bearing to the output shaft.

    104. Object Number: 956325 Size: SH
  104. Install the 6th driven gear to the input shaft.

    105. Object Number: 956317 Size: SH
  105. Install the 6th driven gear snap ring to the output shaft.

    106. Object Number: 956314 Size: SH
  106. Using a dial indicator, measure the radial runout of 6th gear.

    107. Thrust Clearance
    Standard radial runout should be between 0.009-0.50 mm (0.0003-0.0020 in). Maximum runout should not exceed 0.50 mm (0.0020 in).

  107. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.

    108. Object Number: 956308 Size: SH
  108. Using a dial indicator, measure the thrust clearance of 6th gear.

    109. Thrust Clearance
    Standard thrust clearance should be between 0.10-0.60 mm (0.0039-0.0236 in). Maximum clearance should not exceed 0.60 mm (0.0236 in).


    Object Number: 956299 Size: SH
  109. Apply RTV Silicone Sealer GM  P/N  12346240 (Canadian  P/N  10953493) or equivalent to the transaxle case cover.

    110. Object Number: 956285 Size: SH
  110. Install the 9 transmission case cover bolts.

    111. Tighten
    Tighten the 9 bolts to 18 N·m (14 lb ft).


    Object Number: 956278 Size: SH
  111. Coat the 2 retainer bolts (1) with Threadlocker 242 G/M P/N 12345382 (Canadian P/N 10953489) or the equivalent.
  112. Install the 4 bolts and the select lever shaft assembly to the transaxle case.

    113. Tighten
    Tighten the 4 bolts to 18 N·m (14 lb ft).


    Object Number: 956273 Size: SH
  113. Coat the lock ball threads with Threadlocker  242 G/M P/N 12345382 (Canadian P/N 10953489) or the equivalent.
  114. Install the lock ball assembly to the transaxle case.

    115. Tighten
    Tighten the lock ball to 29 N·m (22 lb ft).


    Object Number: 956267 Size: SH
  115. Install the 2 bolts and the selecting bellcrank assembly.

    116. Tighten
    Tighten the 2 bolts to 25 N·m (15 lb ft).

  116. Apply Multi-Purpose grease to the inside surface of the control bellcrank dust cover (1).

    117. Object Number: 956261 Size: SH
  117. Install the 3 bolts and the control cable bracket.

    118. Tighten
    Tighten the 3 bolts to 11 N·m (8 lb ft).


    Object Number: 956253 Size: SH
  118. Install the backup light switch and new gasket to the transaxle case.

    119. Tighten
    Tighten the switch to 40 N·m (29 lb ft).


    Object Number: 956237 Size: SH
  119. Install the bolt and speedometer drive hole cover.

    120. Tighten
    Tighten the bolt to 11 N·m (8 lb ft).


    Object Number: 956234 Size: SH
  120. Install the drain plug and gasket.

    121. Tighten
    Tighten the drain plug to 39 N·m (29 lb ft).


    Object Number: 956228 Size: SH
  121. Install the filler plug and gasket.

    122. Tighten
    Tighten the filler plug to 39 N·m (29 lb ft).