Installation
INSTALL OR CONNECT- Tools Required:
- J 35799-A Fifth Gear Installer
- J 34374 Hub Collar Installer
- J 22912-01 Bearing Remover
- J 35451 Backup Switch Socket
1. Apply GM # 1052271 lightly on parts as assembling.
2. Third gear, needle roller bearing, synchronizer ring, and number 2 hub sleeve assembly to input shaft.
3. Place the synchronizer ring on the gear and align the clutch hub grooves with the projection on the synchronizer ring.
Selective Snap Ring Table (B):
4. Selective snap ring using the snap ring that will allow minimum axial play (Selective Snap Ring Table B).
5. Place the fourth gear synchronizer ring on the gear and align the clutch hub grooves with the projections on the synchronizer ring.
6. Fourth gear and radial ball bearing by using a J 22912-01 bearing remover and a press.
7. Selective snap ring.
- If servicing any hub sleeve assembly.
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.
Important
- Position the key springs so that the end gaps are not lined up.
8. First gear locking ball in shaft.
9. Thrust washer securely over locking ball.
10. Synchronizer ring on gear and align the clutch hub grooves with the projections on the synchronizer ring.
11. First gear and the number 1 hub sleeve.
Selective Snap Ring Table (C):
12. Selective snap ring that will allow the minimum axial play (Selective Snap Ring Table C).
13. Spacer, synchronizer ring, second gear, and needle bearing.
14. Third driven gear.
15. Output gear spacer.
16. Fourth driven gear and bearing.
17. Magnet.
18. Oil receiver with 2 bolts.
19. Differential into transaxle case.
20. To check and adjust side bearing preload, refer to the "Differential."
21. Transaxle case.
Tighten
- Transaxle case bolts to 29 N.m (22 lb. ft.).
- Oil receiver bolt to 11 N.m (97 lb. in.).
22. Input and output shafts together.
23. Shift fork and shift shafts.
24. Place the number 1 and number 2 shift forks into the groove of the number 1 and number 2 hub sleeves and insert the number 1 fork shaft into the number 1 shift fork hole.
25. Two interlock balls into the reverse shift fork.
26. Number 3 shift fork shaft and the reverse shift fork.
27. Number 2 shift fork shaft and the shift head.
28. Three lock bolts.
Tighten
- Lock bolts to 16 N.m (12 lb. ft.).
29. Three shift fork shaft snap rings.
30. Reverse shift arm.
Tighten
- Reverse shift arm bolts to 17 N.m (13 lb. ft.).
31. Reverse idler gear and shaft, aligning idler gear mark.
Important
- Before installing the case, make sure that it is free of any sealing material. Also, be careful not to drop oil on the contacting surfaces.
32. Apply GM #1052756 sealant.
33. Transaxle case as soon as sealant is applied.
34. Sixteen transaxle case bolts.
Tighten
- Transaxle case bolts lo 29 N.m (99 lb. ft.).
35. Lock ball assemblies into case.
36. Apply GM # 1052624 sealant to lock ball assembly plug threads.
37. Plugs.
Tighten
- Plugs to 39 N.m (29 lb. ft.).
38. Apply GM sealant # 1052756 to reverse idler gear shaft lock bolt.
39. Reverse idler gear shaft lock bolt.
Tighten
- Reverse idler shaft lock bolt to 29 N.m (22 lb. ft.).
40. Output shaft bearing snap rings.
41. Snap ring number 2 fork shaft.
42. Rear bearing retainer.
Tighten
- Rear bearing retainer bolts to 27 N.m (20 lb. ft.).
43. Fifth gear with a J 35799-A gear installer.
44. Spacer, needle roller bearing, and fifth gear and synchronizer ring.
45. Support the tip of the input shaft with a spacer to raise the transaxle assembly.
46. Number 3 hub sleeve assembly and shift fork aligning the synchronizer ring slots with the shifting keys. Install the hub sleeve assembly with a J 34374 hub collar installer.
Fifth Gear Selective Snap Ring Table (D):
47. Selective snap ring that allows the minimum axial play (Fifth Gear Selective Snap Ring Table D).
48. Engage gears,
49. Locknut.
Tighten
- Locknut to 118 N.m (87 lb.ft.).
50. Disengage gears.
51. Stake locknut.
52. Number 3 fork shaft lock bolt.
Tighten
- Number 3 fork shaft lock bolt to 16 N.m (12 lb. ft.).
53. Shift and select lever assembly.
54. Apply GM # 1052624 to bolts.
Tighten
- Shift and select lever assembly bolts to 20 N.m (14 lb. ft.).
55. Lock bolt.
Tighten
- Lock bolt to 29 N.m (22 lb. ft.).
56. Apply GM # 1052756 in an even 1 mm bead on the case cover.
57. Transaxle case cover.
Tighten
- Transaxle case cover bolts to 18 N.m (13 lb. ft.).
58. Front Bearing Retainer.
Tighten
- Front bearing retainer bolts to 11 N.m (97 lb. in.).
59. Backup switch using a J 35451 socket.
Tighten
- Backup switch to 40 N.m (30 lb. ft.).
60. VSS into transaxle case; secure with one retaining bolt.
Tighten
- VSS retaining bolt to 11 N.m (97 lb. in.).
61. Release fork and bearing.