Output Shaft Assemble Colorado

Tools Required

Important: 

•	Lubricate all bearings with transmission fluid during assembly.

•	The following steps apply to both the 4WD and the RWD transmission, except where noted.

1. Install the 3rd gear bearing (130) and the 3rd gear (133) on the front of the output shaft.



2. Remove the sleeve from the 3rd/4th synchronizer assembly.
3. Position the synchronizer hub and 3rd gear blocking rings on the output shaft. The smooth side of the hub goes forward, the 4th gear side.
4. Using a hydraulic press, install a new 3rd/4th synchronizer hub on the output shaft.

•	Support the synchronizer hub on the center flange with a suitable tube.

•	Align the blocking rings with the hub and the 3rd gear while pressing.




5. Using J 8001-3 or J 26900-12  (1) and J 26900-13  (2), measure the 3rd gear axial play.

Specification

•	Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in)

•	Maximum Clearance: 0.30 mm (0.0118 in)

5.1.	Position J 8001-3 or J 26900-12  (1) on the top of the gear teeth.

5.2.	Zero the gage.

5.3.	Lift up on the gear to measure the clearance.

6. If the clearance exceeds the maximum, ensure the hub is installed completely.
7. If the clearance exceeds the maximum, inspect the 3rd gear, the output shaft, or the 3rd/4th synchronizer hub for wear.
8. If clearance is lower than the standard clearance, inspect the 3rd gear, the output shaft, or the 3rd/4th synchronizer hub for burrs.
9. Repair or replace the damaged or worn component.



10. Install the 3rd/4th synchronizer sleeve on the hub while pushing in on the inserts. The step shoulder side of the sleeve goes forward to 4th gear.




Important: The retaining ring is a select fit. Always install a new retaining ring.

11. Select the maximum thickness retaining ring for the 3rd/4th synchronizer hub, that will fit in the groove. Refer to 3rd and 4th Gear Synchronizer Retaining Ring Specifications .
12. Install the 3rd/4th synchronizer hub retaining ring.



13. Install the 2nd gear bearing (123) and the 2nd gear (120) on the rear of the output shaft.
14. Remove the 1st gear blocking rings from the 1st/2nd synchronizer assembly. The rings will be installed after pressing on the hub.
15. Install the 1st/2nd synchronizer hub assembly (215) on the output shaft, with the shift fork side of the reverse gear toward 2nd gear.



16. Using a hydraulic press, press the 1st/2nd synchronizer assembly onto the output shaft.

•	Support the synchronizer hub on the center flange.

•	Align the tabs of the blocking rings to the notches in the synchronizer hub and the 2nd speed gear.




17. Using J 8001-3 or J 26900-12  (1) and J 26900-13  (2), measure the 2nd gear axial play.

Specification

•	Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in)

•	Maximum Clearance: 0.30 mm (0.0118 in)

17.1.

Position J 8001-3 or J 26900-12  (1) on the top of the gear teeth.

17.2.

Zero the gage.

17.3.

Lift up on the gear to measure the clearance.

18. If the clearance exceeds the maximum, ensure the hub is installed completely.
19. If the clearance exceeds the maximum, inspect the 2nd gear, the output shaft or the 1st/2nd synchronizer hub for wear.
20. If clearance is lower than the standard clearance, inspect the 2nd gear, the output shaft or the 2nd/3rd synchronizer hub for burrs.
21. Repair or replace the damaged or worn component.




Important: The retaining ring is a select fit. Always install a new retaining ring.

22. Select the maximum thickness retaining ring for the 1st/2nd synchronizer hub, that will fit in the groove. Refer to 1st and 2nd Gear Synchronizer Retaining Ring Specifications .
23. Install the 1st/2nd synchronizer hub retaining ring.



24. Install the 1st gear synchronizer rings. Align the blocking ring tabs to the notches in the hub.



25. Install the 1st gear spacer.



26. Install the 1st gear thrust washer lock pin.



27. Install the following components to the rear of the output shaft:

•	The 1st gear bearing (113)

•	The 1st gear (110)

•	The 1st gear thrust washer (116)

•	The output shaft rear bearing (193)

•	The 5th gear (150)

•	The shorter shoulder goes toward the bearing.




28. Using a hydraulic press and J 6133-A for 4WD, or J 44340 for RWD, press the output rear bearing and the 5th gear onto the output shaft.

•	Ensure the tabs of the blocking rings align to the notches in the synchronizer hub.

•	The retaining ring groove side of the bearing faces 5th gear.




29. Using J 8001-3 or J 26900-12  (1) and J 26900-13  (2), measure the 1st gear axial play.

Specification

•	Standard Clearance: 0.20-0.45 mm (0.0079-0.0177 in)

•	Maximum Clearance: 0.50 mm (0.0197 in)

29.1.

Position J 8001-3 or J 26900-12  (1) on the top of the gear teeth.

29.2.

Zero the gage.

29.3.

Lift up on the gear to measure the clearance.

30. If the clearance exceeds the maximum, ensure the rear output shaft bearing is installed completely.
31. If the clearance exceeds the maximum, inspect the 1st gear, the output shaft or the thrust washer for wear.
32. If clearance is lower than the standard clearance, inspect the 1st gear, the output shaft or the thrust washer for burrs.
33. Repair or replace the damaged or worn component.




Important: The retaining ring is a select fit. Always install a new retaining ring.

34. Select the maximum thickness retaining ring for the 5th gear, that will fit in the groove. Refer to Fifth Gear Retaining Ring Specifications .
35. Install the 5th gear retaining ring.



36. If RWD, install the speed sensor reluctor wheel front retaining ring.
37. Install the speed sensor reluctor wheel locating ball.
38. Install the speed sensor reluctor wheel.
39. Install the speed sensor reluctor wheel rear retaining ring.

Output Shaft Assemble Solstice

Tools Required

Important: Lubricate all bearings with transmission fluid during assembly.

1. Install the 3rd gear bearing (130) and the 3rd gear (133) on the front of the output shaft.



2. Remove the sleeve from the 3rd/4th synchronizer assembly.
3. Position the synchronizer hub and 3rd gear blocking rings on the output shaft. The smooth side of the hub goes forward, the 4th gear side.
4. Using a hydraulic press, install a NEW 3rd/4th synchronizer hub on the output shaft.

•	Support the synchronizer hub on the center flange with a suitable tube.

•	Align the blocking rings with the hub and the 3rd gear while pressing.




5. Using J 8001-3 or J 26900-12  (1) and J 26900-13  (2), measure the 3rd gear axial play.

Specification

•	Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in)

•	Maximum Clearance: 0.30 mm (0.0118 in)

5.1.	Position J 8001-3 or J 26900-12  (1) on the top of the gear teeth.

5.2.	Zero the gage.

5.3.	Lift up on the gear to measure the clearance.

6. If the clearance exceeds the maximum, ensure the hub is installed completely.
7. If the clearance exceeds the maximum, inspect the 3rd gear, the output shaft, or the 3rd/4th synchronizer hub for wear.
8. If clearance is lower than the standard clearance, inspect the 3rd gear, the output shaft, or the 3rd/4th synchronizer hub for burrs.
9. Repair or replace the damaged or worn component.



10. Install the 3rd/4th synchronizer sleeve on the hub while pushing in on the inserts. The step shoulder side of the sleeve goes forward to 4th gear.




Important: The retaining ring is a select fit. Always install a new retaining ring.

11. Select the maximum thickness retaining ring for the 3rd/4th synchronizer hub, that will fit in the groove. Refer to 3rd and 4th Gear Synchronizer Retaining Ring Specifications .
12. Install the 3rd/4th synchronizer hub retaining ring.



13. Install the 2nd gear bearing (123) and the 2nd gear (120) on the rear of the output shaft.
14. Remove the 1st gear blocking rings from the 1st/2nd synchronizer assembly. The rings will be installed after pressing on the hub.
15. Install the 1st/2nd synchronizer hub assembly (215) on the output shaft, with the shift fork side of the reverse gear toward 2nd gear.



16. Using a hydraulic press, press the 1st/2nd synchronizer assembly onto the output shaft.

•	Support the synchronizer hub on the center flange.

•	Align the tabs of the blocking rings to the notches in the synchronizer hub and the 2nd speed gear.




17. Using J 8001-3 or J 26900-12  (1) and J 26900-13  (2), measure the 2nd gear axial play.

Specification

•	Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in)

•	Maximum Clearance: 0.30 mm (0.0118 in)

17.1.

Position J 8001-3 or J 26900-12  (1) on the top of the gear teeth.

17.2.

Zero the gage.

17.3.

Lift up on the gear to measure the clearance.

18. If the clearance exceeds the maximum, ensure the hub is installed completely.
19. If the clearance exceeds the maximum, inspect the 2nd gear, the output shaft or the 1st/2nd synchronizer hub for wear.
20. If clearance is lower than the standard clearance, inspect the 2nd gear, the output shaft or the 2nd/3rd synchronizer hub for burrs.
21. Repair or replace the damaged or worn component.




Important: The retaining ring is a select fit. Always install a new retaining ring.

22. Select the maximum thickness retaining ring for the 1st/2nd synchronizer hub, that will fit in the groove. Refer to 1st and 2nd Gear Synchronizer Retaining Ring Specifications .
23. Install the 1st/2nd synchronizer hub retaining ring.



24. Install the 1st gear synchronizer rings. Align the blocking ring tabs to the notches in the hub.



25. Install the 1st gear spacer.



26. Install the 1st gear thrust washer lock pin.



27. Install the following components to the rear of the output shaft:

•	The 1st gear bearing (113)

•	The 1st gear (110)

•	The 1st gear thrust washer (116)

•	The output shaft rear bearing (193)

•	The 5th gear (150)

•	The shorter shoulder faces toward the bearing.




28. Using a hydraulic press and J 44340 , press the output rear bearing and the 5th gear onto the output shaft.

•	Ensure the tabs of the blocking rings align to the notches in the synchronizer hub.

•	The retaining ring groove side of the bearing faces 5th gear.




29. Using J 8001-3 or J 26900-12  (1) and J 26900-13  (2), measure the 1st gear axial play.

Specification

•	Standard Clearance: 0.20-0.45 mm (0.0079-0.0177 in)

•	Maximum Clearance: 0.50 mm (0.0197 in)

29.1.

Position J 8001-3 or J 26900-12  (1) on the top of the gear teeth.

29.2.

Zero the gage.

29.3.

Lift up on the gear to measure the clearance.

30. If the clearance exceeds the maximum, ensure the rear output shaft bearing is installed completely.
31. If the clearance exceeds the maximum, inspect the 1st gear, the output shaft or the thrust washer for wear.
32. If clearance is lower than the standard clearance, inspect the 1st gear, the output shaft or the thrust washer for burrs.
33. Repair or replace the damaged or worn component.




Important: The retaining ring is a select fit. Always install a new retaining ring.

34. Select the maximum thickness retaining ring for the 5th gear, that will fit in the groove. Refer to Fifth Gear Retaining Ring Specifications .
35. Install the 5th gear retaining ring.



36. Install the reluctor wheel spacer.
37. Install the speed sensor reluctor wheel locating ball.
38. Install the speed sensor reluctor wheel.
39. Install the speed sensor reluctor wheel rear spacer.
40. Install the rear output shaft bearing.