Transmission Assemble

Tools Required

• DT 46496  (DW09940-53111) Gear, Bearing Installer. See Special Tools .
• DT 46497  (DW09943-78210) Bushing, Seal Installer. See Special Tools .
• DT 46612  (DW09913-76010) Bushing, Seal Installer. See Special Tools .
• DT 47515  (DW220-100) Needle Bearing Remover. See Special Tools .
• DT 47516  Needle Bearing Installer. See Special Tools .
• DT 47517  Input Shaft Holder. See Special Tools .
• KM-519  Ring Installer

Fig 1: Input Shaft Oil Seal & Differential Right Side Oil Seal
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Use only a new oil seal.
1. Install the input shaft oil seal using DT 46497  (1). See Special Tools .
IMPORTANT: Coat the transaxle inner parts with gear fluid when installing.
2. Install the differential right side oil seal using DT 46612  . See Special Tools .
Fig 2: Differential Left Side Oil Seal & KM-519
Courtesy of GENERAL MOTORS CORP.
3. Install the oil plate with the bolts.
4. Install the oil gutter with the bolt.
NOTE: Refer to Fastener Notice .
5. Install the oil level plug, including the steel gasket.

   Tighten:  Tighten the oil level plug to 25-30 N.m (18-22 lb ft).

6. Install the differential left side oil seal using KM-519  (2).
Fig 3: Differential Assembly & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
7. Install the differential assembly (1) to the right side of the transaxle case. Position the differential ring gear surface lower than the right side of the transaxle case surface.
Fig 4: Low & High Speed Shift Shaft Assembly
Courtesy of GENERAL MOTORS CORP.
8. Install the low and the high speed shift shaft assembly to the gear unit.
IMPORTANT: Do NOT damage the teeth of the counter shaft pinion and the differential ring gear.
9. Push the gear unit by matching the unit with the input and the counter shaft hole (1).
Fig 5: Reverse Gear Shift Lever & Shaft Assembly
Courtesy of GENERAL MOTORS CORP.
10. Install the 5th reverse gear shift shaft.
IMPORTANT: Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transaxle case - right side.
11. Install the reverse idle gear shaft assembly (2).
12. Install the reverse gear shift lever (1).

    Tighten:  Tighten the bolts to 18-28 N.m (13-21 lb ft).

Fig 6: 3rd-4th Gear Shift Shaft Ball, Spring & 5th Reverse Gear Shift Shaft
Courtesy of GENERAL MOTORS CORP.
13. Install the 3rd-4th gear shift shaft ball and spring (1).

    Tighten:  Tighten the bolt to 10-16 N.m (7-12 lb ft).

IMPORTANT: Install the correct gear shift shaft spring that was marked when removing.
14. Install the 5th reverse gear shift shaft ball and spring (2).

    Tighten:  Tighten the bolt to 10-16 N.m (7-12 lb ft).

Fig 7: Shift, Select, Shaft Needle Bearing, DT 47516 & DT 47515
Courtesy of GENERAL MOTORS CORP.
15. Install the shift and select and shaft needle bearing using DT 47516  (1) with DT 47515  (2). See Special Tools .
Fig 8: Gear Shift & Select Shaft Assemblies
Courtesy of GENERAL MOTORS CORP.
16. Install the gear shift and select shaft assembly.
17. Install the shift and select shaft oil seal (6).
18. Install the shift and select bellows (5).
19. Install the gear select spring assemblies (2).
20. Install the gear shift interlock plate (9).
21. Install the gear shift lever (8).
22. Install the 5th and reverse gear shift cam (3).
23. Install the return spring (7).
24. Install the shift and select shaft (4).
Fig 9: Shift & Select Lever Inner/Outer Pins
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: When installing the inner and outer pins, make the crevices of 2 pins symmetric to each other.
25. Install the shift and the select lever inner and outer pins.
Fig 10: Transaxle Left Side Case & Transaxle Right Side Case Bolts
Courtesy of GENERAL MOTORS CORP.
26. Coat the transaxle case with recommended Transaxle Case Sealant-THREE BOND 1215.
27. Install the transaxle left side case to the transaxle right side case bolts (1).

    Tighten:  Tighten the bolts to 15-22 N.m (11-16 lb ft).

Fig 11: 1st-4th Gear Shift Shaft Ball, Spring & Bolt
Courtesy of GENERAL MOTORS CORP.
28. Install the 1st-2nd gear shift shaft ball and spring using the bolt (1).

    Tighten:  Tighten the bolt to 10-16 N.m (7-12 lb ft).

29. Install the 3rd-4th gear shift shaft ball and spring using the bolt (2).

    Tighten:  Tighten the bolt to 10-16 N.m (7-12 lb ft).

30. Install the reverse idle gear shaft bolt (3).

    Tighten:  Tighten the bolt to 18-28 N.m (13-21 lb ft).

Fig 12: Counter Shaft Bearing Outer Race & DT 46496
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Check if the bearing and the outer race are correctly installed by rotating counter shaft.
31. Install the counter shaft bearing outer race (2) using DT 46496  (1). See Special Tools .
Fig 13: Measuring The Clearance Between Transaxle Case Surface & Bearing Outer Race Using A Straight Ruler
Courtesy of GENERAL MOTORS CORP.
32. Measure the clearance between the transaxle case surface (3) and the bearing outer race (2) using a straight ruler (1) and a gage. Refer to Manual Transmission Specifications .
33. Select a shim so that clearance is within standard.
Fig 14: Counter Shaft 5th Gear & Side Cover Plate
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Use only new screws.
34. Install the side cover plate (1).

    Tighten:  Tighten the screws to 6-7 N.m (53-62 lb in).

IMPORTANT: Position the machined boss side toward the side cover plate.
35. Install the counter shaft 5th gear (3).
Fig 15: Input Shaft & DT 47517
Courtesy of GENERAL MOTORS CORP.
36. Push the shift for toward the 5th gear.
37. Hold the input shaft using DT 47517  (1). See Special Tools .

    Tighten:  Tighten the gear nut to 60-80 N.m (44-59 lb ft).

Fig 16: Input Shaft 5th Gear, Wave Spring & Synchronizer Ring
Courtesy of GENERAL MOTORS CORP.
38. Insert the input shaft 5th gear bearing into the input shaft.
39. Install the 5th gear wave spring and synchronizer ring, matching the synchronizer's oil groove and input shaft punched mark (1).
Fig 17: Synchronizer Springs, Key, Hub Toward Inner Side & Sleeve
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: When assembling the synchronizer sleeve and hub, ensure distance (a) equals distance (b).
40. Install the synchronizer springs to hub (1).
41. Install the synchronizer key (2).
42. Position the longer boss side of hub toward inner side (3).
43. Position the chamfered spline of sleeve toward inner side and install the hub to the sleeve (4).
Fig 18: 5th Gear Fork & Synchronizer Hub Assembly
Courtesy of GENERAL MOTORS CORP.
44. Install the 5th gear fork to the synchronizer hub assembly.
IMPORTANT: Position the longer boss side of hub toward inner side and match the synchronizer key and the hub groove with the input shaft punched mark.
45. Install the 5th gear fork and the synchronizer hub assembly to the input shaft.
Fig 19: Installing 5th Gear Shift Fork Pin Using A Pin Punch & A Hammer
Courtesy of GENERAL MOTORS CORP.
46. Push the 5th gear shift fork toward the 5th gear.
IMPORTANT: Use only new shift fork pin.
47. Install the 5th gear shift fork pin using a pin punch and a hammer (1).
Fig 20: Tightening The Fork Plug
Courtesy of GENERAL MOTORS CORP.
48. Install the 5th gear synchronizer plate.
49. Install the 5th gear snap ring (1).
IMPORTANT: Use only new snap rings.
50. Install the 5th gear fork snap ring (2).
51. Tighten the fork plug after inserting the guide ball into the fork hole.
Fig 21: Side Cover & Bolts
Courtesy of GENERAL MOTORS CORP.
52. Install the side cover (1) with recommended Side Cover Sealant-THREE BOND 1215.

    Tighten:  Tighten the bolts to 8-12 N.m (71-106 lb in).

Fig 22: Shift Interlock Bolt
Courtesy of GENERAL MOTORS CORP.
53. Install the shift interlock bolt.

    Tighten:  Tighten the bolt to 18-28 N.m (13-21 lb ft).

Fig 23: Backup Light Switch & Speedometer Driven Gear Assembly
Courtesy of GENERAL MOTORS CORP.
54. Install the backup light switch (1).

    Tighten:  Tighten the nut to 15-18 N.m (11-13 lb ft).

55. Install the speedometer driven gear assembly (2).

    Tighten:  Tighten the bolt to 4-7 N.m (35-62 lb in).

56. Install the related clutch parts.
Fig 24: Manual Transaxle & DT 46553
Courtesy of GENERAL MOTORS CORP.
57. Remove the transaxle assembly from DT 46553  (1). See Special Tools .
58. Install the transaxle assembly. Refer to Transmission Replacement .