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2001DodgePickup5.9LEngR3500
ServiceManual:MANUALTRANSMISSIONNV4500OVERHAUL

REPAIRINSTRUCTIONS>TRANSMISSIONDISASSEMBLE
ToolsRequired
J861401FlangeandPulleyHoldingTool
J2291201SplitPlateBearingPuller
J38805OutputShaftNutSocket4WDonly
J44707TBarPushPuller
J45545Adapter3/8inchNFto5/8inchNF.
J45546TBarPushPullerLegs16inch.SeeSpecialTools.

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Fig1:RemovingTheShiftLeverAndSeal

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Inordertoremovetheshifttowerthetransmissionmustbein
neutral.
1.Shiftthetransmissiontoneutral.
2.Removetheboltsthatsecuretheshiftlevertothetransmission.
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3.Removetheshiftleverandshifttowerspacer.
Fig2:PryingShiftCoverFromTransmission

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Notethelocationofthebracketsontheshiftcoverboltsinorder
toreinstalltheminthecorrectlocation.
4.Removetheboltsthatsecuretheshiftcovertothetransmission.
5.Usingscrewdriversinthetransmissioncaseslots,prytheshiftcoverfromthetransmission.

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Fig3:HoldingPropellerShaftYoke

CourtesyofGENERALMOTORSCORP.

6.UsingtheJ861401toholdthepropellershaftyoke,loosenthemainshaftnut.

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Fig4:ViewOfYokeAssembly

CourtesyofGENERALMOTORSCORP.

7.ForCmodel,removethefollowingparts:
1.Themainshaftnut
2.Thewasheranddiscard
3.Therubberwasheranddiscard
4.Theyokeassembly

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Fig5:RemovingTheVSSAndSeal

CourtesyofGENERALMOTORSCORP.

8.ForCmodel,removethevehiclespeedsensorandtheOringseal.

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Fig6:Removing/InstallingSpeedSensor

CourtesyofGENERALMOTORSCORP.

9.ForC3500HD,removethevehiclespeedsensorbolt.
10.Removethevehiclespeedsensor.

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Fig7:ViewOfTransmissionExtensionKModel

CourtesyofGENERALMOTORSCORP.

11.ForKmodel,removethetransmissionextensionbolts.
12.Removethetransmissionextension.

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Fig8:ViewOfTransmissionExtensionCModel

CourtesyofGENERALMOTORSCORP.

13.ForC3500HDandCmodel,removethetransmissionextensionbolts.Cmodelshown.
14.Removethetransmissionextension.

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Fig9:Removing/InstallingMainshaftNut&Washer

CourtesyofGENERALMOTORSCORP.

15.ForKmodel,usingtheJ38805(1),removethemainshaftnutandwasher.SeeSpecial
Tools.
16.Discardthewasher.

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Fig10:ViewOfOverdriveGearShiftForkRollPins

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Usethecorrectsizepunchwhenremovingtheshiftforkrollpins.
Ifthepunchistoolarge,itmayflaretheshaftrailandcausehardremovalofthe
shiftfork.
17.Removetheoverdrivegearshiftforkrollpins.

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Fig11:ViewOfOverdriveGearRetainingRing

CourtesyofGENERALMOTORSCORP.

18.Removetheoverdrivegearretainerring.

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Fig12:ViewOfAlignmentMarksOnSynchronizerHub&SynchronizerSleeve

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Forinstallationalignment,scribeanalignmentmarkonthe
synchronizerhubsandsynchronizersleevesbeforeremoving.Topreventthe
synchronizerspringsandstrutsfrombeinglost,donotseparatethesynchronizer
hubsfromthesynchronizersleeves.Keepthesynchronizerclutchgearandthe
blockingringswiththesynchronizerhubs.Organizethecomponentsinorderto
installthecomponentsintheiroriginallocationandposition.
19.Scribeamarkontheoverdrivesynchronizerhubandsynchronizerhubsleeve.

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Fig13:ViewOfOverdriveGearAssembly

CourtesyofGENERALMOTORSCORP.

20.Removetheoverdrivegearassembly,withtheshiftfork,fromthecountershaft.
21.Removetherollerbearing.

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Fig14:ViewOfThrustWasher

CourtesyofGENERALMOTORSCORP.

22.Removethethrustwasher.
23.Removethethrustwasherpinfromthecountershaft.

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Fig15:RemovingReluctorRing

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Onlyremovethespacerandthevehiclespeedsensorreluctor
duringthisprocedure.Thespacerandthespeedsensorreluctorarepressfit.
24.ForC3500HD,removethespacerandthevehiclespeedsensorreluctorusingJ44707
(1),J45546(2),J45545(3)andJ2291201(4)orequivalent.SeeSpecialTools.

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Fig16:VehicleSpeedSensorReluctorSpacer

CourtesyofGENERALMOTORSCORP.

25.ForC3500HD,removethemainshaftoverdrivegearusingJ44707(1),J45546(2),J
45545(3)andJ2291201(4).SeeSpecialTools.

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Fig17:RemovingVSSReluctor

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Onlyremovethevehiclespeedsensorduringthisprocedure.
26.ForCmodel,removethevehiclespeedsensorreluctorusingJ44707(1),J45545(2)and
J2291201(3)orequivalent.SeeSpecialTools.

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Fig18:RemovingMainshaftOverdriveGear

CourtesyofGENERALMOTORSCORP.

27.ForCmodel,removethemainshaftoverdrivegearusingJ44707(1),J45545(2)andJ
2291201(3),orequivalent.SeeSpecialTools.

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Fig19:ViewOfMainshaftRearBearingRetainer

CourtesyofGENERALMOTORSCORP.

28.Removethemainshaftrearbearingretainerbolts.
29.Removethemainshaftrearbearingretainer.
30.Removetheshimorshims.
31.Removethemainshaftrearbearingcup.
32.Movethesynchronizersleevesintotheneutralposition.
33.Positiontheoverdrivegearshiftleverovertothesideandholdinpositionwitharubber
band.

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Fig20:ViewOfInputShaftRetainer

CourtesyofGENERALMOTORSCORP.

34.Forinstallationalignment,marktheinputshaftbearingretainertothetransmissioncase.
35.Removetheinputshaftbearingretainerbolts.
36.Removetheinputshaftretainer.

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Fig21:ViewOfInputShaft&MainDriveGearBearing

CourtesyofGENERALMOTORSCORP.

37.Removetheinputshaft.
38.Removethemaindrivegearbearing.

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Fig22:Removing/InstallingMainshaftAssembly

CourtesyofGENERALMOTORSCORP.

39.Usethefollowingprocedureinordertoremovethemainshaftassemblyfromthecase:
1.Liftthemainshaftandmovetotherearofthecase.
2.Tipthefrontofthemainshaftupandremovethemainshaftfromthecase.

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Fig23:ViewOfCountershaftBearingRetainer

CourtesyofGENERALMOTORSCORP.

40.Removethecountershaftbearingretainerbolts.
41.Removethecountershaftbearingretainer.
42.Removetheshimorshims.
43.Removethecountershaftrearbearingcup.

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Fig24:ViewOfReverseIdlerGear&Shaft

CourtesyofGENERALMOTORSCORP.

44.Removethereverseidlergearandshaft:
1.Usingasuitablepunch,drivethereverseidlergearshafttowardstherearofthe
case.
2.Removethereverseidlergear.
3.Removethethrustwashers.
4.Removethebearing.

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Fig25:RemovingCountershaftRearBearing

CourtesyofGENERALMOTORSCORP.

45.RemovethecountershaftrearbearingusingJ44707(1),J45545(2)andJ2291201(3),
orequivalent.SeeSpecialTools.
Removingthecountershaftrearbearingwillallowthecountershafttobeangledforremoval.

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Fig26:ViewOfCountershaft

CourtesyofGENERALMOTORSCORP.

46.Removethecountershaftfromthetransmissioncase.Slidethecountershaftrearwardand
liftthefrontofthecountershaftoutofthecase.

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Fig27:ViewOfCountershaftFrontBearingCup

CourtesyofGENERALMOTORSCORP.

47.Usingapunchorchisel,removethecountershaftfrontbearingcap.
48.Discardtheremovedbearingcap.
49.Removethecountershaftfrontbearingcup.

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Fig28:ViewOfOverdriveGearShiftLever

CourtesyofGENERALMOTORSCORP.

50.Removetherollpinfromtheoverdrivegearshiftlever.
51.Removetheshiftlevershaft.
52.Removetheoverdrivegearshiftlever.

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REPAIRINSTRUCTIONS>MAINSHAFTDISASSEMBLE
ToolsRequired
J2291201SplitPlateBearingPuller
J36513GearandBearingSeparatorPlate
J44707TBarPushPuller
J44749SplitPlateBearingGearPuller
J44759Adapter3/8NCto5/8NF.SeeSpecialTools.

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Fig1:ViewOf4thGearClutchGear&SynchronizerRing

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Forinstallationalignmentscribeanalignmentmarkonthe
synchronizerhubsandsynchronizersleevesbeforeremoving.Topreventthe
synchronizerspringsandstrutsfrombeinglost,donotseparatethesynchronizer
hubsfromthesynchronizersleeves.Keepthesynchronizerclutchgearandthe
blockingringswiththesynchronizerhubs.Organizethecomponentsinorderto
installthecomponentsintheiroriginallocationandposition.
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1.Positionthemainshaftassemblyinasoftjawviseforeaseofdisassembly.
2.Removethe4thspeedgearclutchgear.
3.Removethe4thspeedgearsynchronizerring.
Fig2:ViewOfMainDriveGearThrustBearing

CourtesyofGENERALMOTORSCORP.

4.Removethemaindrivegearthrustbearing.
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Fig3:Removing3rd/4thSynchronizerHub

CourtesyofGENERALMOTORSCORP.

5.UsingtheJ44707(1),theJ44759(2),andtheJ36513(3),removethe3rd/4th
synchronizerhubfromthemainshaftwiththe3rdspeedgear.
1.PositiontheJ36513(3)behind3rdgear.
2.Ahydraulicpresswithalargebearingsplittercanalsobeused.

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Fig4:ViewOf3rdGearBearing&MainshaftBearingSpacer

CourtesyofGENERALMOTORSCORP.

6.Removethe3rdspeedgearbearing.
7.Removethemainshaftbearingspacer.

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Fig5:MeasuringWearGapFor1stGearPosition

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Thewearofthe1stand2ndspeedsynchronizercanonlybe
measuredcorrectlywhilethesynchronizerandthespeedgearsareinstalledonthe
mainshaft.Thesynchronizerusesafixedinnercone.
8.Inordertomeasuretheweargapforthe1stspeedgearposition,performthefollowing:
1.Engagethe1st/2ndsynchronizersleeveinthe2ndspeedgearposition.
2.Movethesleeve,withlight,even,pressuretowards1stgear.Theinsertswillpress
againsttheblockerring.
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3.Insertthefeelergagebetweenthesynchronizerhubandtheblockerringto
measuretheweargap.
The1stspeedsynchronizerweargapis1.370.31mm(0.0540.012in).
Fig6:MeasuringWearGapFor2ndGearPosition

CourtesyofGENERALMOTORSCORP.

9.Inordertomeasuretheweargapforthe2ndgearposition,performthefollowing:
1.Engagethe1st/2ndsynchronizersleeveinthe1stspeedgearposition.
2.Movethesleeve,withlight,even,pressuretowards2ndgear.Theinsertswillpress
againsttheblockerring.

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3.Insertthefeelergagebetweenthe2ndgearclutchteethandtheblockerringto
measuretheweargap.
The2ndspeedsynchronizerweargapis2.161.14mm(0.0850.045in).
Fig7:ViewOf2ndGearThrustWasherRetainingRing&RetainingPin

CourtesyofGENERALMOTORSCORP.

10.Removethe2ndspeedgearthrustwasherretainerring.
11.Removethe2ndspeedgearthrustwasher.

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12.Removethe2ndspeedgearthrustwasherretainingpin.
Fig8:ViewOf2ndGear

CourtesyofGENERALMOTORSCORP.

13.Removethe2ndspeedgear.

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Fig9:ViewOf2ndGearBearing

CourtesyofGENERALMOTORSCORP.

14.Removethe2ndspeedgearbearing.

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Fig10:ViewOf1st/2ndGearSynchronizerComponents

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Forinstallationalignmentscribeanalignmentmarkonthe
synchronizerhubsandsynchronizersleevesbeforeremoving.Topreventthe
synchronizerspringsandstrutsfrombeinglost,donotseparatethesynchronizer
hubsfromthesynchronizersleeves.Keepthesynchronizerclutchgearandthe
blockingringswiththesynchronizerhubs.Organizethecomponentsinorderto
installthecomponentsintheiroriginallocationandposition.
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15.Removethefollowing1st/2ndgearsynchronizercomponents:
1.The2ndspeedgearsynchronizerouterringretainingringfront(1)
2.The2ndspeedgearsynchronizerinnerring(2)
3.The2ndspeedgearsynchronizercenterring(4)
4.The2ndspeedgearsynchronizerouterring(5)
5.The2ndspeedgearsynchronizerouterringretainingringrear(3)
6.The1st/2ndspeedsynchronizerassembly(6)
7.The1stspeedgearsynchronizerouterring(7)
8.The1stspeedgearsynchronizercenterring(8)
9.The1stspeedgearouterringretainingringfront(9)
10.The1stspeedgearsynchronizerinnerring(10)
11.The1stspeedgearsynchronizerouterringretainingringrear(11)

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Fig11:RemovingRearMainshaftBearing

CourtesyofGENERALMOTORSCORP.

16.UsingahydraulicpressandtheJ44749orequivalent,removetherearmainshaftbearing.
UsetheJ44749underthereversegear.

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Fig12:ViewOfRearMainshaftBearing&ReverseGear

CourtesyofGENERALMOTORSCORP.

17.Removetherearmainshaftbearing.
18.Removethereversegearthrustwasher.
19.Removethereversegear.

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Fig13:ViewOfReverseGearBearing&MainshaftGearSpacer

CourtesyofGENERALMOTORSCORP.

20.Removethereversegearbearing.
21.Removethemainshaftgearspacer.

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Fig14:ViewOfReverseGearClutchHub&SynchronizerRing

CourtesyofGENERALMOTORSCORP.

22.Removetheretainerringforthereversegearclutchhub.
23.Removethereversegearclutchhubandthesynchronizerring.

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Fig15:ViewOf1stGear&Bearing

CourtesyofGENERALMOTORSCORP.

24.Removethe1stspeedgear.
25.Removethe1stspeedgearbearing.

REPAIRINSTRUCTIONS>INPUTSHAFTDISASSEMBLE
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NOTE:ToolsRequired
J2291201SplitPlateBearingPuller
Fig1:RemovingInputShaftBearingCone

CourtesyofGENERALMOTORSCORP.

1.InstalltheJ2291201(1)undertheinputshaftbearing.
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2.RemoveinputshaftbearingconeusingtheJ2291201(1)andahydraulicpress.
Fig2:ViewOfInputShaftBearingRetainerSeal

CourtesyofGENERALMOTORSCORP.

IMPORTANT:
1.Theinputshaftbearingraceisnotserviceable.Iftheraceisfaulty,replace
theinputshaftbearingretainer.
2.Replaceboththeinputshaftbearingandtheinputshaftbearingretainer,if
eitherisfaulty.

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3.Removethesealfromtheinputshaftbearingretainer.
4.Discardtheseal.

REPAIRINSTRUCTIONS>EXTENSIONHOUSINGDISASSEMBLE>C400MODEL
ToolsRequired
J23129UniversalSealRemover
J6125BSlideHammer.SeeSpecialTools.

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Fig1:RemovingMainshaftSeal

CourtesyofGENERALMOTORSCORP.

1.UsingtheJ6125B(1)andtheJ23129(2),removethemainshaftseal.SeeSpecial
Tools.

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Fig2:InstallingMainshaftRearBearingRetainerRing

CourtesyofGENERALMOTORSCORP.

2.Removethemainshaftrearbearingretainingring.

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Fig3:RemovingTheRearBearing

CourtesyofGENERALMOTORSCORP.

3.Usingahammerandapunch,removetherearbearing.Donotreusethebearingafter
removal.

REPAIRINSTRUCTIONS>EXTENSIONHOUSINGDISASSEMBLE>C800MODEL

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Fig1:RemovingMainshaftSeal

CourtesyofGENERALMOTORSCORP.

1.Usingahammerandasuitablepunch,removethemainshaftsealfromthetransmission
extension.

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Fig2:ViewOfMainshaftRearBearingRetainerRing

CourtesyofGENERALMOTORSCORP.

2.Removethemainshaftrearbearingretainerring.

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Fig3:RemovingRearBearing

CourtesyofGENERALMOTORSCORP.

3.Usingahammerandasuitablepunch,removetherearbearing.Donotreusethebearing
afterremoval.

REPAIRINSTRUCTIONS>GEARSANDSHAFTSCLEANINGANDINSPECTION

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Fig1:InspectingMainshaftRacesForBrinelling

CourtesyofGENERALMOTORSCORP.

1.Cleanallthepartsinasuitablesolvent.Airdryalltheparts.
2.Inspectthemainshaftracesforbrinelling.
Thisisatypicaltypeofgeardamage.Indentationsoccurinthecirculativeface,spacedthe
sameastherollerbodies.Thiskindofdamageonlyaffectstheraceshaftandgearbore
raceoftheselectedgear.Affectedareascanbeidentifiedontherollerbodies.Thiskindof
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geardamageisseriousduetotheveryhighincreaseinradialplayonhelicalcutgears.This
canresultincontactpatterndisplacementonthematinggearsandcanevencausetooth
failure.
3.Ifbrinellingispresent,replaceorrepairtheaffectedparts.Brinellingcanbecausedby:
1.Vibrations
2.Vehiclerelatedreciprocatingloads:
1.Drivingatalowroadspeedinahighgear
2.Defectivevibrationdampersoncrankshaft
3.Imbalanceofthepropellershafts
4.Enginerelatedfactors
Ifdieselequipped,incorrectlysetinjectorpump

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Fig2:InspectingMainshaftForFineBrinelling

CourtesyofGENERALMOTORSCORP.

4.Inspectthemainshaftforfinebrinelling.
Finebrinellingisacombinationofbrinellingandwear.Theracesurfacesarebrightly
polished,butshowsignsofconsecutivebrinellingdepressions.
5.Iffinebrinellingispresent,replaceorrepairtheaffectedparts.Finebrinellingcanbecaused
by:
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1.Vibrations
2.Vehiclerelatedreciprocatingloads:
1.Drivingatalowroadspeedinahighgear
2.Defectivevibrationdampersoncrankshaft
3.Imbalanceofthepropellershafts
4.Enginerelatedfactors
Ifdieselequipped,incorrectlysetinjectorpump

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Fig3:InspectingMainshaftForTribologicalOxidation

CourtesyofGENERALMOTORSCORP.

6.Inspectthemainshaftfortribologicaloxidation,whichisinfinitelybrinelledsurface.
Tribologicaloxidationoccursintheshaftbearingracesandthegearboreracesandtakes
theformofuniformradialwear,idlergearwear.Thisdoesnottaketheformofplastic
deformation,butconsistsentirelyofsmoothingcausedbymaterialwearwhichresultsfrom
frettingcorrosion.Theracesurfacesarealwayshighlypolished,withmirrorquality.

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7.Iftribologicaloxidationispresent,replaceorrepairtheaffectedparts.Tribologicaloxidation
canbecausedbythefollowingconditions:
1.Vibrations
2.Vehiclerelatedreciprocatingloads:
1.Drivingatalowroadspeedinahighgear
2.Defectivevibrationdampersoncrankshaft
3.Imbalanceofthepropellershafts
4.Enginerelatedfactors
Ifdieselequipped,incorrectlysetinjectorpump

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Fig4:InspectingMainshaftForTracesOfFretting

CourtesyofGENERALMOTORSCORP.

8.Inspectthemainshaftfortracesoffretting.
Ifcoolingorlubricationintheneedlebearingsinnolongersufficient,itcanleadto
overheating,andcausefrettingcorrosionorseizureofthebearing.
9.Iffrettingispresent,replaceorrepairtheaffectedparts.Frettingcanbecausedby:
1.Lubricationoilthathasundergonethermalaging
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2.Incorrectoilspecifications
3.Inadequateoillevel
4.Towingthevehiclewiththepropellershaftconnected
5.Enginerelatedfactors
Ifdieselequipped,incorrectlysetinjectorpump
Fig5:ViewOfBreakinWearOrRunningInWearOnGears

CourtesyofGENERALMOTORSCORP.

10.Inspectthegearsforbreakinwear,alsoknownasrunninginwear.
Breakinwearisnotconsideredtobedamage.Breakinwearusuallyceasesafterthe
runninginperiodhasexpired,withoutdamagingthecomponents.Roughpeaksproduced
duringmanufacturearewornaway,ortosomeextent,arerolledintothesurface.The
surfacestructure,grindingandshavingmarks,arestillvisible.

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Fig6:ViewOfScratchedGearTeeth

CourtesyofGENERALMOTORSCORP.

11.Inspectthegearteethforscratches.
Scratchesarelinearindentationsontheflank,runninginthedirectionofsliding.
12.Ifscratchesarepresent,replacetheaffectedparts.Scratchescanbecausedby:
1.Dustandabrasiveparticlesinthelubricatingoil,includingthosecausedbyflank
contact
2.Theslidingactionoftheflanks

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Fig7:AbrasiveWearOnGearTeeth

CourtesyofGENERALMOTORSCORP.

13.Inspectthegearteethforabrasivewear.
Themarksleftbythemachiningprocessareerasedfromtheactiveflank.Theentireflank
takesonamattegrayappearance.Substantialchangestakeplaceinthetoothprofileand
clearance,onceabrasivewearhasreachedanadvancedstage.Thisnotonlyincreasesthe
noiselevel,butcanalsocausesecondarydamage.
14.Ifabrasivewearispresent,replacetheaffectedparts.Abrasiveweariscausedby:
1.Oilcontaminationresultingfromwearorsurfacefatigueinotherareasofthe
transmission
2.Sand,sludge,etc.penetratingintothetransmissionfromtheoutside

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Fig8:ViewOfRipplingOrBrinellingOnGearTeeth

CourtesyofGENERALMOTORSCORP.

15.Inspectthegearteethforripplingorbrinelling.
Thepolishedtoothflanksshowsignsofripplelikealterationsinthesurfacestructure,which
runperpendiculartothedirectionofsliding,resemblingawashboard.
16.Ifripplingorbrinellingispresent,replacetheaffectedparts.Ripplingorbrinellingiscaused
by:
1.Acombinationofinadequatelubrication,highflankloads,andlowperipheralspeeds
2.Frictioninducedvibration

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Fig9:LightScoringOnGearTeeth

CourtesyofGENERALMOTORSCORP.

17.Inspectthegearteethforlightscoring.
Lightscoringistherough,partiallyporouslines,orareasalignedinthedirectionofsliding.
Whenthefilmoflubricantistornawaybetweentheflanks,thispermitsdirectmetaltometal
contact,causingseizureorwelding.Theseweldedzonesareimmediatelytornapartagain,
producingthedamageassociatedwithscoring.Scoringinitiallyoccursinareassubjectedto
highhertzfrequencystresses,andhighslidingspeeds,usuallyalongthetoothrootand
toothtip.Lightscoringonlycoversaportionoftheflank.Itisnotstronglydeveloped,andhas
causedonlyinsignificantwearaftersmoothing.
18.Iflightscoringispresent,replacetheaffectedparts.Lightscoringiscausedby:
1.Inadequateoilviscosity
2.Unfavorablegeargeometry
3.Temporarylackoflubricant
4.Surfaceroughness

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5.Faultyheattreatmentofthegears
Fig10:SevereScoringOnGearTeeth

CourtesyofGENERALMOTORSCORP.

19.Inspectthegearteethforseverescoring.
Severescoringisthesameaslightscoring,exceptlargeareasofthetoothflankare
affected.Atanadvancedstage,theflankmayheatuptosuchanextent,thatlocalized
discoloringoccurs.
20.Ifseverescoringispresent,replacetheaffectedparts.Severescoringiscausedby:
1.Inadequateoilviscosity
2.Unfavorablegeargeometry
3.Temporarylackoflubricant
4.Surfaceroughness
5.Faultyheattreatmentofthegears

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Fig11:ViewOfFlankFatigueOnGears

CourtesyofGENERALMOTORSCORP.

21.Inspectthegearsforflankfatigue,causinggrayspots.
Grayspotsarelocalizedpittingsontheflank,causedbymaterialfatigue,andextremelyfine
pittingsformedontheloadbearingflanks.Iftheyareincluster,theyappeartothenaked
eyeasmattegraystaining.Underhighmagnification,alargenumberofmicroscopiccracks
becomevisibleontheflank.Pittingsoriginatingfromthesecracks,maycreatethe
appearanceoflocalflankwear.Mostofthegrayspotsarelocatedintherootzoneofthe
gearteeth.
22.Ifgrayspotsarepresent,replacetheaffectedparts.Grayspotsarecausedby:
1.Materialfatigue
2.Contactpressure
3.Slidingmovement
4.Compositefriction

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Fig12:SlightPittingOnGearTeeth

CourtesyofGENERALMOTORSCORP.

23.Inspectthegearteethforslightpittings.
Slightpittingsareporelikeareasofindividualpittingsontheflank,causedbymaterial
fatigue.Usually,slightpittingsareonlypresentintherootzoneoftheflank.Slightpittings
mayceaseaftertheruninstage.Achangeinoperatingconditionsmayalsostopcontinued
developmentofslightpitting.

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Fig13:PittedGearTeeth

CourtesyofGENERALMOTORSCORP.

24.Inspectthegearteethforpittings.
Pittingsarematerialfatigueontheflank.Thetotalpittingsurfacemaybecomesolarge,that
smoothrunningisconsiderablyimpaired,ortheremainingflankface,stillbearingtheload,
willsoonbedestroyedbywear.
25.Ifpittingsarepresent,replacetheaffectedparts.Pittingiscausedbythefollowing
conditions:
1.Exceedingtheslidingandrollingstressesforthematerial
2.Incorrectoilviscosity
3.Excessiveoperatingtemperature

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Fig14:IdentifyingSpallingOnGears

CourtesyofGENERALMOTORSCORP.

26.Inspectthegearsforspalling.
Spallingisextensive,triangularpitsontheflank,thatspreadfromazoneofgrayspots,ora
finelineofpitsattheroot.Thedepthoftheexposedsurfaceisrelativelyconstant
throughout.Furthercracksmayextendfromthepitsatanangle.Insomecases,the
damagemayevenprogressintothetipzone,causingtipdamage.
27.Ifspallingispresent,replacetheaffectedparts.Spallingiscausedby:
1.Exceedingtheslidingandrollingstressesforthematerial
2.Incorrectoilviscosity
3.Excessiveoperatingtemperature

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Fig15:ViewOfOverheatedGears

CourtesyofGENERALMOTORSCORP.

28.Inspectthegearsforoverheatingdamage.
Signsofoverheatingarethegray,blue,blackdiscolorationofthegear,burntoil,and
reducedhardness.Duetothereductioninhardness,thereisscored,orgroovedflankwear
inthedirectionofsliding,particularlyinthetipandrootzones.Ifthereisextreme
overheating,thematerialsoftens,causingdistortionofthegearteeth,suchasbentteeth
andthermaldeformation.
29.Ifdamagefromoverheatingispresent,replaceorrepairtheaffectedparts.Overheatingis
causedby:
1.Temporaryorcompletelackoflubrication,suchaslowoillevel
2.Veryhighperipheralspeeds
3.Insufficienttoothclearance

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Fig16:ViewOfGearChangeDamageOnSelectorTeeth

CourtesyofGENERALMOTORSCORP.

30.Inspecttheselectorteethofthegearsforgearchangedamage.
Thetoothedgesarewornandchipped,andinsomecases,affectedbyplasticdeformation
asaresultofhighshiftloads,raggededges.Suchseveredeformationoftheselectorteeth
edgeswillcausehardgearshiftchanges.Thesplineflanksmayalsoshowsignsofwear
resemblingfrettingcorrosion.
31.Ifgearchangedamageispresent,replaceorrepairtheaffectedparts.Gearchange
damageiscausedbythefollowingconditions:
1.Correspondingspeedsofgearsnotadequatelymatched
2.Operatingthetransmissionincorrectly
3.Incorrectclutchoperation

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Fig17:IdentifyingGearCorrosion

CourtesyofGENERALMOTORSCORP.

32.Inspectthegearsforcorrosion.
Signsofcorrosionarethebrown,red,orblackspots,sometimeswithlocalmateriallosson
theflank.Ifcorrosionhasnotcausedmateriallosstotheflank,theslidingandrollingaction
oftheflankcanhelptoremovesomeofthecorrosion.
33.Ifcorrosionissevere,replacetheaffectedparts.Corrosioniscausedby:
1.Waterorsaltwaterenteringthetransmission
2.Condensationformingunderunfavorableoperatingconditions
3.Oilagingandthedecompositionofcorrosioninhibitors

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Fig18:BrinellingOnRollerRacesOfGears

CourtesyofGENERALMOTORSCORP.

34.Inspecttheidlergearsforbrinelling.
Thistypeofdamageoccursontherollerracesoftheidlergears.Itischaracterizedbywhat
appearstobetheimpressionofthebearingrollers.Ifthebearingonlyperformsasupporting
functionoveralongperiodoftime,thereisnotmovementbetweenthegearandthe
supportingshaft,thebearingcontactareasmayshowsignsoffrettingcorrosion.
35.Replaceanygearsshowingbrinelling.

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Fig19:LocatingBearingAssembly

CourtesyofGENERALMOTORSCORP.

36.Cleanthecountershaftinasuitablecleaningsolvent.Airdrythecountershaft.
37.Inspectthecountershaftforcracks.
38.Replaceacrackedcountershaft.
39.Inspectthecountershaftgearsforthefollowingconditions:
1.Scuffedgearteeth
2.Nickedgearteeth
3.Burredgearteeth
4.Brokengearteeth
5.Highspots,smallshinyspotsonthegearteethmatingsurfaces,thatcouldcausegear
noise

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40.LubricatethecountershaftbearingswithSyntheticManualTransmissionFluidGMP/N
12346190(CanadianP/N10953477).
41.Replacethebearingassembly(1)ifanyofthefollowingconditionsexist:
1.Roughnessofrotation
2.Burrs
3.Pittedcondition
42.Replacethebearingrace,andinspectthematingparts,ifthefollowingconditionsexist:
1.Scoring
2.Wear
3.Discolorationfromoverheating

REPAIRINSTRUCTIONS>SYNCHRONIZERSCLEANINGANDINSPECTION
IMPORTANT:
Onlydisassemblethesynchronizersleevefromthesynchronizerhubifthereisa
suspectedgearshiftconcern.
Forinstallationalignment,scribeanalignmentmarkonthesynchronizerhubsand
synchronizersleevesbeforedisassembling.
Markthesynchronizersclutchgearsandtheblockingringswiththecorresponding
gear,forcorrectdiagnosticinspections.
Installthesynchronizercomponentsinthesamelocation,ifreusing.

3rd/4thSpeedGearSynchronizerDisassembly

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Fig1:ViewOfSynchronizer3rd/4thGear

CourtesyofGENERALMOTORSCORP.

1.Laythesynchronizeronashoptowel,withtheselectorteethdown.
2.Coverwiththeshoptowel.
3.Slidethesynchronizersleeveoffthesynchronizerhub.
4.Removethethreespringsandthethreeinserts.

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5th(Overdrive)SpeedGearSynchronizerDisassembly
Fig2:ViewOfSynchronizer5th/OverdriveGear

CourtesyofGENERALMOTORSCORP.

1.Laythe5thspeedgearassemblyonashoptowel,withthegearsidedown.
2.Coverwiththeshoptowel.
3.Slidethesynchronizersleeveoffthesynchronizerhub.

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4.Removethethreespringsandthethreeinserts.
1st/2ndSpeedGearSynchronizerDisassembly
Fig3:ViewOfSynchronizer1st/2ndGear

CourtesyofGENERALMOTORSCORP.

1.Laythe1st/2ndspeedgearassemblyonashoptowel,withthe2ndspeedgearsideup.The
taperedsideofthesleeveisthe2ndspeedgearside.
2.Coverwiththeshoptowel.
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3.Slidethesynchronizersleeveoffthesynchronizerhub.
4.Removethefourspringsandthefourinserts.
ReverseSpeedGearSynchronizerDisassembly
Fig4:ViewOfSynchronizerReverseGear

CourtesyofGENERALMOTORSCORP.

1.Laythereversespeedgearassemblyonashoptowel,withthereversegeardown.

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2.Coverwiththeshoptowel.
3.Slidethesynchronizersleeveoffthesynchronizerhub.
4.Removethethreespringsandthethreeinserts.
Fig5:ViewOfSteppedEffectOnTheSynchronizersTeeth

CourtesyofGENERALMOTORSCORP.

1.Cleanallthepartsinasuitablecleaningsolvent.Airdryalltheparts.
2.Inspectthesynchronizersleevesforaslidingfitonthesynchronizerhubs.
3.Replacethe3rdand4thgearsynchronizerhubthatdoesnotrequireaforcefitonthe
mainshaftsplines.
4.Inspectthesynchronizerhubforwearontheexternalsplines.Asteppedeffectontheteeth,
duetowear,maycauseshiftconditions.
5.Inspectthe3rdand4thgearsynchronizerhubforaforcefitonthemainshaftsplines.
6.Replaceawornhub.

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7.Correctthecausesuchas,butnotlimitedto,thefollowing:
1.Enginerelatedvibrations
2.Drivingatalowspeedinahighgear
3.Defectivevibrationdamperorcrankshaft
4.Incorrectlysetinjectorpump
8.Inspecttheinsertsandspringsforwearordamage.
Fig6:InspectingClutchGearTeeth

CourtesyofGENERALMOTORSCORP.

9.Inspectthemainshaftdrivegearclutchgearteethforwear.
10.Inspecttheinputshaftclutchgearteethforwear.
11.Inspecttheclutchgearfor4thgear,reversegear,andoverdrivegearwear.

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Fig7:InspectingSynchronizerSleeveTeeth

CourtesyofGENERALMOTORSCORP.

12.Inspectthesynchronizersleeveteeth(1)forthefollowing,whichmaycauseshiftconditions:
1.Gratedteeth
2.Chippedoffteeth
3.Bluntedteeth

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13.Inspectthesynchronizersleevedetentstops(2)forwearorforbeingchippedoff.
14.Replacethesynchronizerassemblyiftheteethorstopsshowtheaboveconditions.
Fig8:Inspecting1st/2ndSynchronizerBlockerRingsForWear

CourtesyofGENERALMOTORSCORP.

15.Inspectthethreepiece1st/2ndsynchronizerblockerringsforwear.
16.Replacetheblockerringassemblyifthemiddleringgroovesarewornaway.

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Fig9:InspectingSynchronizerBlockerRingsForWearOrDamage

CourtesyofGENERALMOTORSCORP.

17.Inspectallofthesynchronizerblockerringsforwornshiftteeth.
18.Inspecttheblockerringsforwornfrictionmaterial.
19.Replacethesynchronizerringassemblyifanyoftheaboveconditionsarepresent.

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Fig10:MeasuringBlockerRingToGearClearance

CourtesyofGENERALMOTORSCORP.

20.Measurethecapbetweenthevericalfacesoftheblockingringteethandthesynchronizer
clutchgearasfollows:
1.Assemblethecorrectblockerringtothecorrectgear.
2.Applypressuretotheblockerringtofullyseatthering.
3.Usingafeelergauge,measurebetweentheblockerringteethandtheteethonthe
gear.
1.1stgear,betweenthehubandouterring,1.370.31mm(0.0540.012in)
2.2ndgear2.161.14mm(0.0850.045in)
3.3rdgear1.730.76mm(0.0680.030in)
4.4thgear2.101.19mm(0.0790.047in)
5.Overdrivegear1.831.07mm(0.0720.042in)

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6.Reversegear2.241.47mm(0.0880.058in)
21.IfaNEWblockerringisused,andthestandardclearancecannotbeobtained,replacethe
gear.
3rd/4thSpeedGearSynchronizerAssembly
Fig11:ViewOfSynchronizer3rd/4thGear

CourtesyofGENERALMOTORSCORP.

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1.Laythesynchronizerhubonthe3rdspeedgearsynchronizerblockingringandclutchgear.
Theringandgearwillholdthehubup.
2.Slidethesynchronizersleeveonthesynchronizerhub.
1.Alignthelargetoothwiththelargeslotinthesleeve.
2.Thesleevecangoeitherdirection,ifitisnotmarked.
3.Usingasmallscrewdriver,installthethreespringsandthethreeinserts.
4.Movethesleevetotheneutralposition,toholdthespringsandinsertsinposition.
5th(Overdrive)SpeedGearSynchronizerAssembly

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Fig12:ViewOfSynchronizer5th/OverdriveGear

CourtesyofGENERALMOTORSCORP.

1.Laythe5thspeedgearassembly,withthegearsidedown,ontheworkbench.
2.Slidethesynchronizersleeveonthesynchronizerhub,withthetaperedsideofthesleeve
towardsthegear.
3.Usingasmallscrewdriver,installthethreespringsandthethreeinserts.
4.Movethesleevetotheneutralposition,toholdthespringsandinsertsinposition.
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1st/2ndSpeedGearSynchronizerAssembly
Fig13:ViewOfSynchronizer1st/2ndGear

CourtesyofGENERALMOTORSCORP.

1.Laythe1st/2ndspeedgearassemblyonthe1stspeedgearsynchronizerinnerandmiddle
rings.Theringswillholdthehubup.
2.Slidethesynchronizersleeveonthesynchronizerhub.
1.Alignthesleevetothehub.
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2.Thesleevewillfitinonlyonedirectiononthehub.
3.Thetaperedsideofthesleevefacesup,ortowardsecondgear.
3.Usingasmallscrewdriver,installthefourspringsandthefourinserts.
4.Movethesleevetotheneutralposition,toholdthespringsandinsertsinposition.
ReverseSpeedGearSynchronizerAssembly
Fig14:ViewOfSynchronizerReverseGear

CourtesyofGENERALMOTORSCORP.

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1.Laythereversespeedgearassembly,withthereversegeardown,ontheworkbench.
2.Slidethesynchronizersleeveonthesynchronizerhub.
1.Alignthesleevetothehub.
2.Thesleevewillfitinonlyonedirectiononthehub.
3.Thetaperedsideofthesleevefacestowardreversegear.
3.Usingasmallscrewdriver,installthethreespringsandthethreeinserts.
4.Movethesleevetotheneutralposition,toholdthespringsandinsertsinposition.

REPAIRINSTRUCTIONS>FRONTANDREARHOUSINGS
1.Removetheoldsealantfromthehousings.
2.Cleanthetransmissionhousingsinasuitablecleaningsolvent.Airdrythehousing.
3.Inspectthehousingforthefollowingconditions:
1.Cracks
2.Damagedthreads
3.Nickedmountingsurfaces
4.Burrs
5.Scratches
4.Replaceacrackedhousing.
5.Cleanupdamagedthreadswiththecorrectsizetap.
6.Replacethehousingifscratches,groovesorscoringcannotberemovedwithasoftstoneor
acrocuscloth.
7.Inspectthemachinedmatingsurfacesforflatness.Checkthematingsurfaceswithastraight
edge.

REPAIRINSTRUCTIONS>BEARINGSANDSPACERSCLEANINGANDINSPECTION

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Fig1:ViewofBearings&Spacers

CourtesyofGENERALMOTORSCORP.

NOTE:Donotallowthebearingstospin.Turnthemslowlybyhand.Spinning
thebearingsmaydamagetheraceandtherollers.
1.Cleanallthebearingpartsinasuitablesolvent.Airdryalltheparts.
2.Inspectthebearingsandjournalsforroughnessandunusualwearordamage.
3.Inspectthemainshaftbearingjournalsforwear.
4.Inspectthemainshaftspeedgearbearingsforwear.
5.Inspectthemaindrivegearpilotbearingrollersforwear.
6.Replacepartswhichshowsignsofexcessivewear.
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7.Donotfilesurfaceswhichhavebeenhardenedandprecisionground.
8.Replacewornordamagedbearings.
9.Replacematedbearingpartswhenonlyonepartisdamaged.
10.Lubricatethebearingsafterinspection.UseSyntheticManualTransmissionFluidGMP/N
12346190(CanadianP/N10953477).

REPAIRINSTRUCTIONS>SHIFTSHAFTANDSHIFTFORKSCLEANINGAND
INSPECTION
Fig1:InspectingShiftShaft&ShiftForks

CourtesyofGENERALMOTORSCORP.

IMPORTANT:Theshiftrailsandtheshiftforksarenotserviceable.Theshiftcover
canbedisassembledforinspect.Theshiftforkinterlockpins,rollpins,andtheshiftbar
housingexpansionplugsareserviceable.
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Removetheoldsealantfromtheshiftcover.
Cleanallthepartsinasuitablecleaningsolvent.Airdrytheparts.
Inspecttheshiftshaftsforwearorscoring.
Inspecttheshiftshaftforksforwearthroughthehardenedsurface,scoring,ordistortion.The
shiftforkpadsonthe5th/Reverseshiftforkareserviceable.
Inspecttheshiftfork,thebarpoppetplungersandthespringsforwearordistortion.
Inspecttheshiftshaftsocketassemblycomponentsforwearordistortion.
Replacetheshiftcoverifthereisexcessiveweartotheshiftforks,shiftshafts,ortotheshift
shaftsockets.

REPAIRINSTRUCTIONS>MAINSHAFTASSEMBLE
ToolsRequired
J22828InputandCountershaftRaceInstaller
J22834AExtensionHousingSealInstaller.SeeSpecialTools.

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Fig1:ViewOf1stGear&Bearing

CourtesyofGENERALMOTORSCORP.

1.Positionthemainshaftinasoftjawvice,withtheoutputendup.
2.Lubricatethe1stspeedgearbearingwithtransmissionfluid.
3.Installthe1stspeedgearbearing.
4.Installthe1stspeedgear,withthesectorteethfacingdown.

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Fig2:ViewOfReverseGearClutchHub&SynchronizerRing

CourtesyofGENERALMOTORSCORP.

5.Installthereversegearclutchgearandthesynchronizerring.Ensurethatthesideofthe
synchronizerwithringteetharetowardthemainshaftshoulder.
6.Installthereversegearclutchgearretainerring.

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Fig3:ViewOfReverseGearBearing&MainshaftGearSpacer

CourtesyofGENERALMOTORSCORP.

7.Installthemainshaftbearingspacerontopoftheretainingring.
8.Lubricatethereversespeedgearbearingwithtransmissionfluid.
9.Installthereversespeedgearbearing.

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Fig4:ViewOfRearMainshaftBearing&ReverseGear

CourtesyofGENERALMOTORSCORP.

10.Installthereversegearassembly.Rotatetheassemblyuntilthegeardropsintothefully
seatedposition.Ifthesynchronizerassemblywasdisassembled,thesynchronizersleeve
mustbereinstalledwiththetaperofthesleevetowardthereversegear.
11.Installthereversegearthrustwasher.
12.Positiontherearmainshaftbearingonthemainshaft.
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Fig5:InstallingRearMainshaftBearing

CourtesyofGENERALMOTORSCORP.

13.UsingahydraulicpressandtheJ22828,installtherearmainshaftbearing.
14.Turnthemainshaftoverandinstallitintoasoftjawvice,withthefrontfacingup.

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Fig6:ViewOf1st/2ndGearSynchronizerComponents

CourtesyofGENERALMOTORSCORP.

15.Installthefollowing1st/2ndgearsynchronizercomponents:
1.The1stspeedgearsynchronizerouterringretainingring(11)inthelowergroove
2.The1stspeedgearsynchronizerinnerring(10)
3.The1stspeedgearouterringretainerring(9)inthesecondgroove

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4.The1stspeedgearsynchronizercenterring(8)
Turn,toaligninfirstgear.
5.The1stspeedgearsynchronizerouterring(7)
6.The1st/2ndspeedsynchronizerassembly(6)
Thetaperedsideofthesleevefacesup.
7.Turnthe1stspeedgearsynchronizerringstoaligninthesynchronizerassembly.
8.The2ndspeedgearsynchronizerouterring(5)
Turnthering,toalignthetabsinthesynchronizerassembly.
9.The2ndspeedgearsynchronizercenterring(4)
10.The2ndspeedgearsynchronizerouterringretainingring(3)inthethirdgroove
11.The2ndspeedgearsynchronizerinnerring(2)
12.The2ndspeedgearsynchronizerouterringretainingring(1)inthetopgroove

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Fig7:ViewOf2ndGearBearing

CourtesyofGENERALMOTORSCORP.

16.Lubricatethe2ndspeedbearingwithtransmissionfluid.
17.Installthe2ndspeedgearbearing.

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Fig8:ViewOf2ndGear

CourtesyofGENERALMOTORSCORP.

18.Installthe2ndspeedgear.Turnthegear,toaligntheinnersynchronizerringtabsinthe
gear.

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Fig9:ViewOf2ndGearThrustWasherRetainingRing&RetainingPin

CourtesyofGENERALMOTORSCORP.

19.Installthefollowingparts:
1.The2ndspeedgearthrustwasherretainingpin
2.The2ndspeedgearthrustwasher
Besurethethrustwasherisseatedonthegearandtheretainingpin.
3.The2ndspeedgearthrustwasherretainerring
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Fig10:ViewOf3rdGearBearing&MainshaftBearingSpacer

CourtesyofGENERALMOTORSCORP.

20.Installthemainshaftbearingspacer.
21.Lubricatethe3rdspeedgearbearingwithtransmissionfluid.
22.Installthe3rdspeedgearbearing.

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Fig11:Installing3rd/4thSynchronizer

CourtesyofGENERALMOTORSCORP.

23.UsingtheJ228342AofJ22834A,installthe3rd/4thsynchronizerinthemainshaft.See
SpecialTools.Alignthesynchronizerringstothesynchronizerwhileinstalling.

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Fig12:ViewOf4thGearClutchGear&SynchronizerRing

CourtesyofGENERALMOTORSCORP.

24.Installthemaindrivegearthrustbearing.
25.Installthe4thspeedgearsynchronizerring.
26.Installthe4thspeedgearclutchgear.

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REPAIRINSTRUCTIONS>INPUTSHAFTASSEMBLE
ToolsRequired
J22828InputandCountershaftRaceInstaller
J38801InputShaftSealInstaller
Fig1:InstallingInputShaftBearingCone

CourtesyofGENERALMOTORSCORP.

1.Ifremoved,installanewinputshaftbearingconeusingtheJ22828(1)ontotheinputshaft.

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Fig2:InstallingMainDriveGearSeal

CourtesyofGENERALMOTORSCORP.

2.UsingtheJ38801(1),installthemaindrivegearsealintotheinputshaftretainer.

REPAIRINSTRUCTIONS>TRANSMISSIONASSEMBLE
ToolsRequired
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J8001DialIndicatorSet
J8092UniversalDriverHandle
J861401FlangeandPulleyHoldingTool
J22828InputandCountershaftRaceInstaller
J25070HeatGun500750F
J2690013MagneticIndicatorBase
J38805OutputShaftNutSocket.SeeSpecialTools.
J38856BearingCupandRetainerInstaller.SeeSpecialTools.

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Fig1:ViewOfOverdriveGearShiftLever

CourtesyofGENERALMOTORSCORP.

1.Installthefollowingparts:
1.Theoverdrivespeedgearshiftlever
2.Theshiftlevershaft
Thenotchesthatretaintheoverdrivespeedgearshiftforkaretotheoutsideofthe
case.
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3.Theshiftleverretainingpin
Fig2:HoldingOverdriveSpeedGearShiftLeverBackWithRubberBand

CourtesyofGENERALMOTORSCORP.

2.Installarubberband,inordertoholdtheoverdrivespeedgearshiftleverbackoutofthe
way.

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Fig3:InstallingCountershaftFrontBearingCup

CourtesyofGENERALMOTORSCORP.

3.UsingtheJ38856,installthecountershaftfrontbearingcup.SeeSpecialTools.

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Fig4:ViewOfCountershaft

CourtesyofGENERALMOTORSCORP.

4.Installthecountershaftassemblyintothetransmissioncase.Positiontherearofthe
countershaftintotherearcountershaftbearingbore,thenmovethefrontofthecountershaft
intoposition.

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Fig5:InstallingCountershaftRearBearing

CourtesyofGENERALMOTORSCORP.

5.Installthecountershaftrearbearing,usingthefollowingprocedure:
1.Positionthetransmissioncasewiththefrontofthecasedown.
2.Liftthecountershaft,andplaceablockofwoodbetweenthefrontofthe
countershaftandthetransmissioncase.
3.UsingtheJ22828,installthecountershaftrearbearing.
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Fig6:ViewOfReverseIdlerGear&Shaft

CourtesyofGENERALMOTORSCORP.

6.Installthefollowingparts:
1.Thereverseidlergear
2.Thebearing
3.Thewashers
4.Thereverseidlergearshaft

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Thestepontheshaftalignstowardthecountershaft,andisinstalledflushtothe
case.
Fig7:ViewOfCountershaftBearingRetainer

CourtesyofGENERALMOTORSCORP.

7.Positionthetransmissionwiththefrontofthecasedown.
8.Positionthecountershaftinthecountershaftfrontbearingcup.
9.Installthecountershaftrearbearingcup.

NOTE:RefertoFastenerNoticeinCautionsandNotices.

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10.Temporarilyinstallthecountershaftbearingretainerandthebolts.
Tighten:Tightenthecountershaftbearingretainerboltsto35N.m(26lbft).
Fig8:MeasuringCountershaftEndPlay

CourtesyofGENERALMOTORSCORP.

11.Measurethecountershaftendplay.Usethefollowingprocedure:
1.UsingJ2690013(2),settheJ8001(1)ontheendofthecountershaft.

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2.ZeroouttheJ8001.
3.Usingascrewdriver,ortheequivalent,liftthecountershaftandrecordthe
measurement.
Thecountershaftendplayshouldbe0.050.15mm(0.0020.006in).
4.Removethecountershaftrearbearingretainerandbolts.
5.Addshim(s)underthebearingretainertoachievethecorrectendplay.
Fig9:InstallingCountershaftBearingRetainer

CourtesyofGENERALMOTORSCORP.

12.ApplythreadlockerGMP/N12345493tothecountershaftretainerbolts.
13.Installthecountershaftbearingretainerandbolts.
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Tighten:Tightenthecountershaftbearingretainerboltsto35N.m(26lbft).
Fig10:InstallingFrontCountershaftBearingCap

CourtesyofGENERALMOTORSCORP.

14.UsingtheJ38856withtheJ8092,installaNEWfrontcountershaftbearingcap.When
properlyinstalled,theouterlipofthecapwillbeflushwithcase.

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Fig11:Removing/InstallingMainshaftAssembly

CourtesyofGENERALMOTORSCORP.

15.Installthemainshaftassemblyintothetransmissioncase.

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Fig12:ViewOfInputShaft&MainDriveGearBearing

CourtesyofGENERALMOTORSCORP.

16.Lubricatethemaindrivegearbearingwithtransmissionfluid.
17.Installthemaindrivegearbearingandtheinputshaftintothetransmissioncase.

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Fig13:AligningTheBearingRetainerOilDrainHoleAtTheTopDeadCenterPosition

CourtesyofGENERALMOTORSCORP.

18.ApplyathinlayerofRTVsealerGMP/N12345739,ortheequivalent,totheinputshaft
retainermatingsurface.Excessiveamountscouldplugthebearingoilpassage.

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Fig14:ViewOfInputShaftRetainer

CourtesyofGENERALMOTORSCORP.

19.Installtheinputshaftretainer.Positiontheretainerwiththeoilholeatthetopcenterposition.
20.ApplythreadlockerGMP/N12345493totheinputshaftretainerbolts.
21.Installtheinputshaftretainerbolts.
Tighten:Tightentheinputshaftretainerboltsto22N.m(16lbft).

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Fig15:ViewOfMainshaftRearBearingRetainer

CourtesyofGENERALMOTORSCORP.

22.Positionthetransmissionwiththefrontofthecasedown.
23.Installthemainshaftrearbearingcup.
24.Temporarilyinstallthemainshaftrearbearingretainerandbolts.
Tighten:Tightenthemainshaftrearbearingretainerboltsfingertightonly.

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Fig16:MeasuringMainshaftEndPlay

CourtesyofGENERALMOTORSCORP.

25.Measurethecountershaftendplay.Usethefollowingprocedure:
1.UsingJ2690013(2),settheJ8001(1)ontheendofthemainshaft.
2.ZeroouttheJ8001.
3.Usingascrewdriver,ortheequivalent,liftthemainshaftandrecordthe
measurement.
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Themainshaftendplayshouldbe0.050.15mm(0.0020.006in).
4.Removethemainshaftrearbearingretainerandbolts.
5.Addshim(s)underthebearingretainertoachievethecorrectendplay.
Fig17:ViewOfMainshaftRearBearingRetainer

CourtesyofGENERALMOTORSCORP.

26.ApplythreadlockerGMP/N12345493tothemainshaftrearbearingretainerbolts.
27.Installthemainshaftrearbearingretainerandbolts.
Tighten:Tightenthemainshaftrearbearingretainerboltsto35N.m(26lbft).

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Fig18:ViewOfThrustWasher

CourtesyofGENERALMOTORSCORP.

28.Installthethrustwasherpininthecountershaft.
29.Installthethrustwasher.Thetaperedsidefacestowardthefrontofthetransmission.

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Fig19:ViewOfOverdriveGearAssembly

CourtesyofGENERALMOTORSCORP.

30.Lubricatetheoverdrivegearbearingwithtransmissionfluid.
31.Installtheoverdrivespeedgearbearing.
32.Installtheoverdrivespeedgearassemblyontotheoverdrivespeedshiftshaftandthe
countershaft.Slidetheoverdrivespeedgearforkandtheoverdrivespeedgearassembly
ontotheshiftshaft.

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Fig20:ViewOfOverdriveGearRetainingRing

CourtesyofGENERALMOTORSCORP.

33.Installtheoverdrivespeedgearclutchgearretainerring.

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Fig21:ViewOfOverdriveGearShiftForkRollPins

CourtesyofGENERALMOTORSCORP.

34.Installtheoverdrivespeedgearshiftforkrollpins.Supportthefork,anddrivetherollpins
downwardfromthetopofthefork.

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Fig22:ViewOfMainshaftOverdriveGear

CourtesyofGENERALMOTORSCORP.

CAUTION:Whenhandlingpartsthathavebeenpreheatedforinstallation
purposes,alwayswearleatherweldinggloveswithaminimumamountofhandling
time.Failuretowearleatherglovesmayresultinsevereskinburnsorpersonal
injury.
35.UsingtheJ25070,orequivalent,heatthemainshaftoverdrivegear,thevehiclespeed
sensorreluctorwheel(RWDmodels),andthemainshaftspacer(HD3500models),for
fifteenminutes.
36.Installthemainshaftoverdrivegearonthemainshaft.
37.UsingtheJ22828,ensurethemainshaftoverdrivegearisfullyseatedagainstthe
mainshaftrearbearing.

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Fig23:ViewOfVSSReluctorWheel

CourtesyofGENERALMOTORSCORP.

38.(RWDmodels)Installthevehiclespeedsensorreluctorwheelonthemainshaft.
39.UsingtheJ22828,ensurethevehiclespeedsensorreluctorwheelisfullyseatedagainst
themainshaftoverdrivegear.

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Fig24:InstallTheMainshaftSpacerOnTheMainshaft

CourtesyofGENERALMOTORSCORP.

40.(HD3500model)Installthemainshaftspaceronthemainshaft.
41.UsingtheJ22828,ensurethemainshaftspacerisfullyseatedagainstthereluctorwheel.

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Fig25:Removing/InstallingMainshaftNut&Washer

CourtesyofGENERALMOTORSCORP.

42.Shiftthetransmissionintotwogears,tolockthemainshaft.
43.(4WDmodels)UsingtheJ38805(1),installaNEWmainshaftwasherandthenut.See
SpecialTools.
Tighten:Tightenthemainshaftnutto540N.m(400lbft).

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Fig26:InstallTheRearOutputShaftRearBearing

CourtesyofGENERALMOTORSCORP.

44.(RWDmodels)UsingJ38807(2)andJ8092(1),installtherearoutputshaftrearbearing
inthetransmissionextension.

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Fig27:InstallingMainshaftRearBearingRetainerRing

CourtesyofGENERALMOTORSCORP.

45.(RWDmodels)Installthemainshaftrearbearingretainerring.

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Fig28:InstallingTransmissionExtensionKModel

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46.Cleananyoilfromthesealingsurfaceofthetransmissionextensionandtherearofthe
case.
47.ApplyRTVsealerGMP/N12345739onthematingsurfacesofthetransmissionextension.
48.(4WDmodels)Installthetransmissionextensiontothetransmissioncase.
Tighten:Tightentheboltsto54N.m(40lbft).

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Fig29:ViewOfTransmissionExtensionCModel

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49.(RWDmodels)Installthetransmissionextensiontothetransmissioncase.
Tighten:Tightentheboltsto54N.m(40lbft).

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Fig30:InstallingMainshaftSeal

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50.(RWDmodels)UsingtheJ22834A,installanewmainshaftsealinthetransmission
extension.SeeSpecialTools.

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Fig31:RemovingTheVSSAndSeal

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51.(C800models)Installthevehiclespeedsensor(VSS).LubricatetheOringforeaseof
installation.
Tighten:TightentheVSSto16N.m(12lbft).

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Fig32:InstallingVSS

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52.(C400models)InstalltheVSS.LubricatetheOringseal.
53.InstalltheVSSbolt.
Tighten:TightentheVSSboltto16N.m(12lbft).

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Fig33:ViewOfYokeAssembly

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54.(RWDmodels)Installtheyokeassembly.
55.(RWDmodels)InstallaNEWsplineseal,aNEWwasher,andthenut.

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Fig34:HoldingPropellerShaftYoke

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56.UsetheJ861401toholdthepropellershaftyoke.
57.Shiftthetransmissioninto1stgear,toaidthetighteningoftheyokenut.
Tighten:Tightentheyokenutto441N.m(325lbft).
58.FillthetransmissiontotheproperlevelwithSyntheticManualTransmissionFluidGMP/N
12346190.

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Fig35:ApplyingSealantToTransmissionCoverMatingSurfaces

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59.ApplyRTVsealerGMP/N12345739,ortheequivalent,tothematingsurfacesofthe
transmissioncover.

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Fig36:InstallingShiftCoverToTransmissionCase

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60.Installtheshiftcovertothetransmissioncase.
61.Installtheshiftcoverboltsandthebracketstotheiroriginallocation.
Tighten:Tightentheboltsto27N.m(20lbft).

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Fig37:ApplyingSealantToCoverSideOfShiftTowerSpacer

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62.ApplyRTVsealerGMP/N12345739,ortheequivalent,totheshiftcoversideoftheshift
towerspacer.

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Fig38:RemovingTheShiftLeverAndSeal

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63.Installtheshifttowerspacertotheshiftcover.
64.Installtheshiftlevertothespacer.
65.Installtheshiftleverboltsandbushings.
Tighten:Tightentheboltsto11N.m(97lbin).

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