Output Shaft Assemble

Tools Required

• J 6133-A  Bearing Race Installer. See Special Tools .
• J 8001-3  Dial Indicator
• J 26900-12  Dial Indicator - 1-10 mm. See Special Tools .
• J 26900-13  Magnetic Indicator Base
• J 44340  Bearing Installer. See Special Tools .

Fig 1: 3rd Gear Bearing & 3rd Gear
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Lubricate all bearings with transmission fluid during assembly.
• The following steps apply to both the 4WD and the RWD transmission, except where noted.
1. Install the 3rd gear bearing (130) and the 3rd gear (133) on the front of the output shaft.
Fig 2: Output Shaft
Courtesy of GENERAL MOTORS CORP.
2. Remove the sleeve from the 3rd/4th synchronizer assembly.
3. Position the synchronizer hub and 3rd gear blocking rings on the output shaft. The smooth side of the hub goes forward, the 4th gear side.
4. Using a hydraulic press, install a new 3rd/4th synchronizer hub on the output shaft.
   • Support the synchronizer hub on the center flange with a suitable tube.
   • Align the blocking rings with the hub and the 3rd gear while pressing.
Fig 3: Measuring 3rd Gear Axial Play
Courtesy of GENERAL MOTORS CORP.
5. Using J 8001-3  or J 26900-12  (1) and J 26900-13  (2), measure the 3rd gear axial play. See Special Tools .

   Specification: 

   • Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in)
   • Maximum Clearance: 0.30 mm (0.0118 in)
   1. Position J 8001-3  or J 26900-12  (1) on the top of the gear teeth. See Special Tools .
   2. Zero the gauge.
   3. Lift up on the gear to measure the clearance.
6. If the clearance exceeds the maximum, ensure the hub is installed completely.
7. If the clearance exceeds the maximum, inspect the 3rd gear, the output shaft, or the 3rd/4th synchronizer hub for wear.
8. If clearance is lower than the standard clearance, inspect the 3rd gear, the output shaft, or the 3rd/4th synchronizer hub for burrs.
9. Repair or replace the damaged or worn component.
Fig 4: 3rd/4th Synchronizer Sleeve & Inserts
Courtesy of GENERAL MOTORS CORP.
10. Install the 3rd/4th synchronizer sleeve on the hub while pushing in on the inserts. The step shoulder side of the sleeve goes forward to 4th gear.
Fig 5: 3rd/4th Synchronizer Hub Retaining Ring
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The retaining ring is a select fit. Always install a new retaining ring.
11. Select the maximum thickness retaining ring for the 3rd/4th synchronizer hub, that will fit in the groove. Refer to 3rd and 4th Gear Synchronizer Retaining Ring Specifications .
12. Install the 3rd/4th synchronizer hub retaining ring.
Fig 6: 1st/2nd Synchronizer Hub Assembly, 2nd Gear & Bearing
Courtesy of GENERAL MOTORS CORP.
13. Install the 2nd gear bearing (123) and the 2nd gear (120) on the rear of the output shaft.
14. Remove the 1st gear blocking rings from the 1st/2nd synchronizer assembly. The rings will be installed after pressing on the hub.
15. Install the 1st/2nd synchronizer hub assembly (215) on the output shaft, with the shift fork side of the reverse gear toward 2nd gear.
Fig 7: 1st/2nd Synchronizer Assembly
Courtesy of GENERAL MOTORS CORP.
16. Using a hydraulic press, press the 1st/2nd synchronizer assembly onto the output shaft.
    • Support the synchronizer hub on the center flange.
    • Align the tabs of the blocking rings to the notches in the synchronizer hub and the 2nd speed gear.
Fig 8: Checking 2nd Gear Axial Play
Courtesy of GENERAL MOTORS CORP.
17. Using J 8001-3  or J 26900-12  (1) and J 26900-13  (2), measure the 2nd gear axial play. See Special Tools .

    Specification: 

    • Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in)
    • Maximum Clearance: 0.30 mm (0.0118 in)
    1. Position J 8001-3  or J 26900-12  (1) on the top of the gear teeth. See Special Tools .
    2. Zero the gauge.
    3. Lift up on the gear to measure the clearance.
18. If the clearance exceeds the maximum, ensure the hub is installed completely.
19. If the clearance exceeds the maximum, inspect the 2nd gear, the output shaft or the 1st/2nd synchronizer hub for wear.
20. If clearance is lower than the standard clearance, inspect the 2nd gear, the output shaft or the 2nd/3rd synchronizer hub for burrs.
21. Repair or replace the damaged or worn component.
Fig 9: 1st/2nd Synchronizer Hub Retaining Ring
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The retaining ring is a select fit. Always install a new retaining ring.
22. Select the maximum thickness retaining ring for the 1st/2nd synchronizer hub, that will fit in the groove. Refer to 1st and 2nd Gear Synchronizer Retaining Ring Specifications .
23. Install the 1st/2nd synchronizer hub retaining ring.
Fig 10: 1st Gear Synchronizer Rings
Courtesy of GENERAL MOTORS CORP.
24. Install the 1st gear synchronizer rings. Align the blocking ring tabs to the notches in the hub.
Fig 11: 1st Gear Bearing Spacer
Courtesy of GENERAL MOTORS CORP.
25. Install the 1st gear spacer.
Fig 12: 1st Gear Thrust Washer Lock Pin
Courtesy of GENERAL MOTORS CORP.
26. Install the 1st gear thrust washer lock pin.
Fig 13: Output Shaft Components
Courtesy of GENERAL MOTORS CORP.
27. Install the following components to the rear of the output shaft:
    • The 1st gear bearing (113)
    • The 1st gear (110)
    • The 1st gear thrust washer (116)
    • The output shaft rear bearing (193)
    • The 5th gear (150)

      The shorter shoulder goes toward the bearing.

Fig 14: Pressing Output Rear Bearing & 5Th Gear Onto Output Shaft
Courtesy of GENERAL MOTORS CORP.
28. Using a hydraulic press and J 6133-A  for 4WD, or J 44340  for RWD, press the output rear bearing and the 5th gear onto the output shaft. See Special Tools .
    • Ensure the tabs of the blocking rings align to the notches in the synchronizer hub.
    • The retaining ring groove side of the bearing faces 5th gear.
Fig 15: Measuring 1st Gear Axial Play
Courtesy of GENERAL MOTORS CORP.
29. Using J 8001-3  or J 26900-12  (1) and J 26900-13  (2), measure the 1st gear axial play. See Special Tools .

    Specification: 

    • Standard Clearance: 0.20-0.45 mm (0.0079-0.0177 in)
    • Maximum Clearance: 0.50 mm (0.0197 in)
    1. Position J 8001-3  or J 26900-12  (1) on the top of the gear teeth. See Special Tools .
    2. Zero the gauge.
    3. Lift up on the gear to measure the clearance.
30. If the clearance exceeds the maximum, ensure the rear output shaft bearing is installed completely.
31. If the clearance exceeds the maximum, inspect the 1st gear, the output shaft or the thrust washer for wear.
32. If clearance is lower than the standard clearance, inspect the 1st gear, the output shaft or the thrust washer for burrs.
33. Repair or replace the damaged or worn component.
Fig 16: 5th Gear Retaining Ring
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The retaining ring is a select fit. Always install a new retaining ring.
34. Select the maximum thickness retaining ring for the 5th gear, that will fit in the groove. Refer to Fifth Gear Retaining Ring Specifications .
35. Install the 5th gear retaining ring.
Fig 17: Speed Sensor Reluctor Wheel Front Retaining Ring, Wheel & Ball
Courtesy of GENERAL MOTORS CORP.
36. If RWD, install the speed sensor reluctor wheel front retaining ring.
37. Install the speed sensor reluctor wheel locating ball.
38. Install the speed sensor reluctor wheel.
39. Install the speed sensor reluctor wheel rear retaining ring.