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Transaxle Reassembly

  1. Place transaxle case in holding fixture. Using Seal Installer (J-26540), drive input shaft seal into case. Lubricate bearing races. Using Bearing Installer (J-33371) and Driver (J-8092), press input shaft bearing race into clutch housing.
  2. Using Bearing Installer (J-7817) and driver, press output shaft bearing race into clutch housing. Using Bearing Installer (J-8611-01) and driver, press differential bearing race into housing.
  3. Apply grease to interlock pins. Install pins on clutch housing. See Fig 1 . Install reverse shift bracket on clutch. Use 3rd-4th shaft rod to align bracket to housing. Install retaining bolts and tighten. Make sure rod operates smoothly.
  4. Install differential assembly. Install input shaft, output shaft with 3rd-4th shift fork and shaft as an assembly. The 3rd-4th shift shaft is installed into raised collar of reverse shift lever bracket.
    Fig 1: Installing Interlock Pins
    G95E55644Courtesy of GENERAL MOTORS CORP.
  5. Install 1st-2nd shift fork onto synchronizer sleeve and insert shifter shaft into reverse shift lever bracket. Align hole in shift fork with shaft and install roll pin. Stake roll pin into place.
  6. Install reverse lever on shift bracket. Ensure that interlock pin is installed in 5th gear shift shaft. Install reverse and 5th gear shift shaft and at same time, engage reverse shaft with reverse shift lever. Install reverse idler shaft and gear. Make sure reverse lever is engaged in gear collar.
  7. Position outer bearing races on input shaft, output shaft, and differential bearings. Position Shim Selection Kit (J-33373) on bearing races. See Fig 2 . Kit gauges are marked "INPUT", "OUTPUT", and "DIFFERENTIAL".
  8. Install 7 spacers, provided in kit, around perimeter of clutch housing. Install bearing and shim retainer on shafts. Tighten bolts to 11-16 ft. lbs. (15-22 N.m). Stake screws to retaining plate.
  9. Carefully position transaxle case over gauges and on spacers. Install 7 bolts provided with kit and tighten bolts to 10 ft. lbs. (14 N.m). Ensure case is seated on spacers. See Fig 2 .
    Fig 2: Installing Shim Selection Kit
    G95F55645Courtesy of GENERAL MOTORS CORP.
  10. Rotate each gauge to seat bearings. Rotate differential case through 3 revolutions in each direction. With 3 gauges compressed, measure gap between outer sleeve and base pad using available shim sizes. Use the largest shim that can be placed in gap and drawn through without binding. See Fig 3 .
  11. Input shaft shim should be one size smaller than the largest shim that will fit in gap. The differential should use a shim three sizes larger than that which will smoothly fit in gap. The output shaft should use the largest shim that can be placed in gap and drawn through without binding.
  12. Preload shims for input shaft are available in thicknesses of .0394-.0977" (1.00-2.48 mm) in .0016" (.04 mm) increments. Preload shims for output shaft are available in thicknesses of .0457-.0961" (1.16 -2.44 mm) in .0031" (.08 mm) increments. Preload shims for differential are available in thicknesses of .0426-.0788" (1.08-2.00 mm) in .0016" (.04 mm) increments.
  13. When each of the 3 shims have been selected, remove transaxle case, spacers, and gauges. Position shims selected for input shaft, output shaft, and differential into bearing race bores in case. Using Bearing Installer (J-24256-A) and Driver (J-8092), install rear input shaft bearing race.
    Fig 3: Determining Preload Shim Size
    G95H55647Courtesy of GENERAL MOTORS CORP.
  14. Using Bearing Installer (J-33370) and driver, install rear output shaft bearing race. Lubricate rear differential case bearing race. Using Bearing Installer (J-8611-01) and driver, install rear differential case bearing race. Press bearing race until seated in bore.
  15. Apply a 1/8" bead of sealant to mating surfaces of clutch housing and transaxle case. Make sure magnet is installed in transaxle case. Install transaxle case on clutch housing.
  16. Install reverse idle shaft bolt into transaxle case. Install 14 case bolts and tighten in diagonal sequence. Install drive axle seals. Lubricate output shaft thrust washer. Using bench press and Driver (J-33374), install thrust washer and collar onto output shaft.
  17. Install 5th gear on input shaft. Install needle bearing, 5th gear, blocker ring, hub/sleeve assembly with shift fork in its groove and back plate on output shaft. Align shift fork on shift shaft and install roll pin. Install input and output shaft nuts and tighten. Stake nuts after tightening.
  18. Install detent balls and detent springs for reverse, 1st-2nd, 3rd-4th, and 5th gears. Install retaining bolts and tighten. Install 1st-2nd gear switch. Install short pin and then long pin into 3rd-4th gear switch hole. Install 3rd-4th gear switch.
  19. Install gasket, gearshift box assembly, and tighten bolts. Make sure transaxle shifts properly before installing rear cover. Install gasket, rear cover, and tighten bolts.
  20. Install clutch fork assembly (if removed). Lubricate and install bushing into upper hole using Bushing Replacer (J-28412). Install oil seal. Install clutch release bearing.
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