Transmission Disassemble

Tools Required

• DT 46496  (DW09940-53111) Gear, Bearing Installer. See Special Tools .
• DT 46553  (DW220-010A) Transaxle Fixture. See Special Tools .
• DT 47515  (DW220-100) Needle Bearing Remover. See Special Tools .

Fig 1: Manual Transaxle & DT 46553
Courtesy of GENERAL MOTORS CORP.
1. Remove the manual transaxle. Refer to Transmission Replacement .
2. Position the manual transaxle to a transaxle stand using DT 46553  (1). See Special Tools .
Fig 2: Manual Transaxle, Mounting Bracket & Bolts
Courtesy of GENERAL MOTORS CORP.
3. Remove the related clutch parts.
4. Remove the manual transaxle mounting bracket bolts (1).
5. Remove the manual transaxle mounting bracket nut (3).
6. Remove the manual transaxle mounting bracket (2).
Fig 3: Backup Light Switch, Nut, Speedometer Driven Gear Assembly & Bolt
Courtesy of GENERAL MOTORS CORP.
7. Remove the backup light switch nut (1).
8. Disconnect the backup light switch (4).
9. Remove the speedometer driven gear assembly bolt (3).
10. Remove the speedometer driven gear assembly (2).
Fig 4: Shift Interlock Bolt
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Remove the shift interlock bolt. Otherwise, the gear shift and shaft assembly can not be removed.
11. Remove the shift interlock bolt.
Fig 5: Side Cover Bolts & Side Cover
Courtesy of GENERAL MOTORS CORP.
12. Remove the side cover bolts (1).
13. Remove the side cover using a rubber hammer (2).
14. Remove the sealant on the side cover and the transaxle case.
Fig 6: 5th Gear Shift Fork Plug, Snap Ring & Synchronizer Plate
Courtesy of GENERAL MOTORS CORP.
15. Remove the 5th gear shift fork plug (1).
16. Remove the 5th gear shift fork guide ball using a magnet.
17. Remove the 5th gear shift fork snap ring (2).
18. Remove the 5th gear synchronizer plate.
Fig 7: Removing Fork Pin Using A Pin Punch & A Hammer
Courtesy of GENERAL MOTORS CORP.
19. Shift the shift fork to the 5th gear.
20. Remove the fork pin using a pin punch and a hammer (1).
21. Remove the 5th gear shift fork pin.
Fig 8: Input Shaft 5th Gear Fork & Synchronizer Hub Assembly
Courtesy of GENERAL MOTORS CORP.
22. Pull and remove the input shaft 5th gear fork and the synchronizer hub assembly together (1).
23. Remove the sleeve, key and spring from the synchronizer hub assembly.
Fig 9: Input Shaft 5th Gear, Wave Spring & Synchronizer Ring
Courtesy of GENERAL MOTORS CORP.
24. Pull and remove the input shaft 5th gear, wave spring and synchronizer ring together (1).
25. Remove the 5th gear bearing.
Fig 10: Shifting Yoke Using A Driver To Engage 1st Gear & 3rd Gear Or 2nd Gear & 4th Gear
Courtesy of GENERAL MOTORS CORP.
26. Shift yoke using a driver to engage the 1st gear and the 3rd gear or the 2nd gear and the 4th gear (2).
27. Remove the caulking and the nut (1).
Fig 11: Countershaft 5th Gear
Courtesy of GENERAL MOTORS CORP.
28. Remove the countershaft 5th gear (1).
Fig 12: Side Cover Plate & Screws
Courtesy of GENERAL MOTORS CORP.
29. Remove the side cover plate screws (1).
30. Remove the side cover plate (2).
31. Remove the counter shaft bearing shim.
Fig 13: 1st-5th Gear Shift Shaft Spring & Ball
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: There is a difference between the 5th reverse gear shift shaft spring and the others. Mark it to distinguish easily when installing.
32. Remove the bolt and remove the 5th reverse gear shift shaft spring and ball (3).
33. Remove the bolt and remove the 3rd-4th gear shift shaft spring and ball (1).
34. Remove the bolt and remove the 1st and 2nd gear shift shaft spring and ball (2).
Fig 14: Reverse Idle Gear Shaft & Bolt
Courtesy of GENERAL MOTORS CORP.
35. Remove the reverse idle gear shaft bolt.
Fig 15: Right & Left Side Of Case
Courtesy of GENERAL MOTORS CORP.
36. Remove the bolts from the left side case (1).
37. Remove the bolts from the right side of case (2).
38. Remove the left side case by hitting with a rubber hammer lightly.
39. Remove the sealant on the case.
40. Remove the transaxle case - left.
Fig 16: Reverse Gear Shift Lever & Bolt
Courtesy of GENERAL MOTORS CORP.
41. Remove the bolts (1).
42. Remove the reverse gear shift lever (2).
Fig 17: Reverse Idle Gear & Shaft
Courtesy of GENERAL MOTORS CORP.
43. Push the reverse idle gear toward the inner case.
44. Pulling shaft and remove the reverse idle gear and shaft (1).
45. Remove the reverse idle gear from the shaft assembly.
Fig 18: 5th Reverse Gear Shift Shaft
Courtesy of GENERAL MOTORS CORP.
46. Remove the 5th reverse gear shift shaft (1).
Fig 19: Shift & Select Lever Inner/Outer Pins
Courtesy of GENERAL MOTORS CORP.
47. Remove the shift and select lever inner and outer pins.
Fig 20: Gear Shift & Select Shaft Assemblies
Courtesy of GENERAL MOTORS CORP.
48. Remove the gear shift and select shaft assembly.
49. Remove the shift and select shaft (4).
50. Remove the gear select spring assemblies (2).
51. Remove the gear shift interlock plate (9).
52. Remove the gear shift lever (8).
53. Remove the 5th and reverse gear shift cam (3).
54. Remove the return spring (7).
55. Remove the shift and select bellows (5).
56. Remove the shift and select shaft oil seal (6).
Fig 21: Shift, Select Shaft Needle Bearings & DT 47515
Courtesy of GENERAL MOTORS CORP.
57. Remove the shift and select shaft needle bearings using the DT 47515  (1). See Special Tools .
Fig 22: Gear Unit & Shift Shaft Assembly
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Be careful not to damage the teeth of the counter shaft pinion and the differential ring gear.
58. Remove the gear unit and the shift shaft assembly together (1).
59. Remove the high and the low speed shift shaft assembly from the gear unit.
Fig 23: Inserting Wooden Stick Into Lower Side Of Differential
Courtesy of GENERAL MOTORS CORP.
60. Insert a wooden stick into the lower side of the differential (2).
61. Remove the differential assembly by moving it right and left (1).
Fig 24: Differential Left Side Oil Seal & Components
Courtesy of GENERAL MOTORS CORP.
62. Remove the bolt (1).
63. Remove the oil gutter (2).
64. Remove the bolts (5).
65. Remove the oil plate (3).
66. Remove the differential left side oil seal using a hammer and a copper chisel (4).
67. Remove the related parts of the transaxle case, left side.
Fig 25: Counter Shaft Bearing Outer Race & Components
Courtesy of GENERAL MOTORS CORP.
68. Remove the oil level plug, including the steel gasket (2).
69. Remove the counter shaft bearing outer race using a hammer and DT 46496  (1). See Special Tools .
Fig 26: Differential Left Side Oil Seal & Components
Courtesy of GENERAL MOTORS CORP.
70. Remove the related parts of the transaxle case - right side.
71. Remove the input shaft oil seal using a screwdriver (2).
72. Remove the differential left side oil seal using a hammer and a copper chisel (1).