Transmission Assembly
Assemble (Figures 46 through 53)Tool Required:
J 25070 Heat Gun (2WD models only)
J 36515-10 Retainer Alignment Cables (2WD models only)
J 36502 4WD Oil Seal Installer
J 36502-2A 4WD Seal Protector
J 36515 Assembly Pallet
J 36515-16 Countershaft Adapter
J 36515-15 Mainshaft Adapter
J 3289-20 Base Holding Fixture
J 8763-02 Holding Fixture C-Clamp
J 8763-21 Balance Bracket for C-Clamp
J 6133-01 Speedometer Rotor Installer (2WD models only)
J 36824 Transmission Holding Fixture Adapters
NOTICE:
For steps 13, 18, 30, 36, 39, 40, 41, 42, and 44, refer to "Notice" at the beginning of this bulletin.
1. Pilot bearing (3) into input shaft (1) (figure 46).
A. Turn the smaller diameter of the bearing cable toward the input shaft.
B. Retain with TRANSJEL (TM) J 36850 or equivalent.
2. Position onto J 36515-15/J 36515 fixture:
A. Input shaft (1).
B. Pilot bearing (3).
C. Synchronizer ring (2).
D. Mainshaft assembly (4) (2WD) or (5) (4WD).
3. Position countershaft (53) onto J 36515-16 fixture (figure 14).
4. Reverse idler assembly (46).
5. Output shaft bearing assembly (33) (2WD models only).
6. New snap ring (44).
7. Install on main shaft assembly (4) or (5):
A. First-second shift fork (101).
B. 5-reverse shift fork (100).
Important
^ Steps 8 through 13 are for 2WD models only. Steps 14 and is for 4WD models only.
8. Snap-ring (43) (figure 14) (2WD models only).
9. Speed sensor rotor (45) HEATED (2WD models only) (figure 47).
^ If necessary seat with J 6133-01.
Important
^ The 2WD rear housing output shaft bearing assembly bore MUST be heated for 3 to 5 minutes with J 25070 before assembly (figure 48).
10. J 36515-10 through bolt (304) and (305) holes in the rear housing (figure 49) (2WD models only). Screw into the output shaft bearing retainer (302). Notch in retainer towards oil delivery tube assembly (307).
11. Bearing (203). (2WD models only.)
A. Install in bearing race (202) of the housing, with the smaller diameter of the bearing cage into the bearing race.
B. Retain with TRANSJEL(TM) J 36850 or equivalent.
Important
^ Press each roller towards the race to secure them for easier assembly
12. Rear housing assembly (300) (2WD models only).
A. Make sure the reverse idler shaft is lined up with the hole in the case.
B. Rotate back and fourth while pulling down.
C. Pull up on J 36515-10 while installing rear housing.
Important
^ Bring the housing straight down. If resistance is felt at about 7 mm (1/4 in.), then the rollers (203) are cocked. Repeat above procedures to install. Do not force housing down.
13. Bolts (304) (figure 50) (2WD models only).
A. Apply pipe sealant with Teflon(TM) GM P/N 1050280 or equivalent to the bolt holes of the rear housing.
B. Apply threadlocker GM P/N 12345382 to bolt threads.
C. Remove J 36515-10.
Tighten
^ Bolts (304) to 22 N-m (16 lbs.ft.).
14. Bearing (203) (figure 13) (4WD models only).
A. Install in bearing race (202) of the housing.
B. Install the smaller diameter of the bearing cage into the bearing race.
C. Retain with TRANSJEL(TM) J 36850 or equivalent.
D. Press each roller towards the race to secure them for easier assembly.
15. Rear housing assembly (301) (4WD models only) (figure 13).
A. Make sure the reverse idler shaft is lined up with the hole in the case.
B. Rotate back and forth while pulling down.
Important
Bring the housing straight down. If resistance is felt at about 7 mm (1/4 in.), then the rollers (203) are cocked. Repeat above procedures to install. Do not force the housing down.
- Install seal protector J 36502-2A onto output shaft.
16. Output shaft oil seal (320) using J 36502 (figure 51) (4WD models only).
A. Fill between the seal lip with chassis grease.
B. Remove seal protector J 36502-2A.
Important
The remaining assembly procedures apply to both 2WD and 4WD models.
17. Lay the unit down on the workbench and remove
18. Idler shaft support (310) and bolt (311) (figure 52).
A. Line up the bolt threads in the idler shaft support with bolt hole.
B. Apply pipe sealant with Teflon(TM) GM P/N 1052080 or equivalent to the bolt hole.
C. Apply threadlocker GM P/N 1235382 or equivalent to the bolt threads.
D. Hold reverse idler shaft against idler support while torquing.
Tighten
^ Bolt to 22 N-m (16 lbs.ft.).
19. Position J 8763-21, J 8763-02, and J 36824 onto the transmission case (figure 11).
20. Third-fourth shift fork (102) onto the third-fourth synchronizer sleeve (8).
^ Align all three insert notches.
21. Shift shaft (108) into third-fourth shift fork (102) with detent reliefs in shaft pointing out (figures 1 and 2).
22. Shift lever (104) and block-out bushing (103) onto the shift shaft (108).
23. Shift shaft (108) through first-second shift fork (101).
24. Biasing spring (109), anti-rotation bracket (110), and shift socket (114) onto the shift shaft (108). Slide the shift shaft (108) all the way into the case (300) or (301).
25. New roll pin (105) into shift lever.
^ Rotate shift shaft and shift lever/blockout bushing assembly until roll pin holes are aligned and horizontal.
^ Install pin (105) until flush with the shift lever (104).
26. Fork insert detent spring (106) and ball (107) into hole in the shift lever (104).
^ Rotate shift shaft (108) counter-clockwise until shift lever (104) is almost into fifth-reverse insert notch.
^ Install spring (106) and ball (107) into shift lever (104).
^ Rotate shift shaft (108) until shift lever (104) aligns with 3-4 insert.
27. Shift socket (114) to shift shaft roll pin (113).
^ Align holes in the shift socket (114) and shift shaft (108).
^ Drive roll pin (113) until it is flush with the bottom of the shift socket (114).
Important
Use the second (middle) roll pin hole on the MG5 transmission and the rear roll pin hole on the MY2 transmission.
28. Biasing spring (109) tangs to the anti-rotation bracket (110) using a screw driver. Make sure the shifter is in neutral and anti-rotation bracket rollers (112) are level with machined surface of case opening.
29. Gasket eliminator to both sides of the anti-rotation roller plate and install to case opening. Thin side of plate as viewed from the top should be installed towards the left side of the transmission.
30. Shift tower (136) and bolts (204) (figure 33).
Tighten
^ Shift tower bolts to 10 N-m (89 lbs.in.).
31. Countershaft bearing (35) to countershaft race (figure 10).
Important
A. Install smaller diameter of bearing cage into the bearing race.
B. Press each roller into cage and retain with TRANSJEL(TM) J 36850 or equivalent.
C. Apply TRANSJEL(TM) J 36850 or equivalent to bearing race on input shaft.
32. Front housing (200) (figure 10).
Important
Bring the housing straight down. If resistance is felt at about 7 mm (1/4 in.), then the rollers (35) are cocked. Repeat steps 28, 29, and 30. Do not force down the housing.
33. Two dowels (321) (figures 1 and 2).
34. Bolts (312) (figure 10).
^ Do not tighten.
^ Tip vertically.
35. NEW snap ring (210) (figure 9). It may be necessary to pull out on the input shaft to install the snap ring. Apply gasket maker GM P/N 1052943 or equivalent to the inside of the bolt hole pattern.
Important
DO NOT APPLY too much gasket maker around the oil drain back hole. This could clog the hole causing a low fluid flow through the bearing resulting in premature bearing failure.
36. Input shaft bearing retainer assembly (205) and six bolts (204). Make sure oil drain back hole is lined up with the hole in the housing.
Tighten
^ Bolts (204) to 8.5 N-m (75 lbs.in.).
37. Shift shaft detent plunger (243), shift shaft detent spring (244), and plug (245) using brass drift (figure 53).
^ Apply pipe sealant with Teflon(TM) GM P/N 1052080 or equivalent to the plug.
38. Install new O-ring (315) onto electronic speed sensor assembly (316) (2WD models only). Coat the O-ring with a thin film of transmission fluid.
39. Electronic speed sensor assembly (316) and bolt (317) (2WD models only).
Tighten
^ Bolt (317) to 9 N-m (80 lbs.in.).
40. Backup lamp switch assembly (313). Apply pipe sealant with Teflon(TM) GM P/N 1052080 or equivalent to the threads.
Tighten
^ Switch (313) to 9 N-m (80 lbs.in.).
41. Remove J 8763-02 and J 36824.
Tighten
^ Bolts (312) (figure 5) to 35 N-m (26 lbs.ft.).
42. Blockout bushing anchor bolt (236) (figures 1 and 2).
Tighten
^ Anchor bolt to 25 N-m (18 lbs.ft.).
43. Fill transmission with Synchromesh Transmission Fluid or the equivalent.
44. Oil fill plug (222).
Tighten
^ Oil fill plug (222) to 60 N-m (44 lbs.ft.).