Installation Procedure

Tools Required 

• J 36850 Transjel® Transmission Assembly Lubricant. See Special Tools and Equipment .
• J 8614-01 Countershaft Driven Gear Holder. See Special Tools and Equipment .
• J 35425 Rack Seal and Bearing Installer. See Special Tools and Equipment .
• J 34826 Hub Nut Socket. See Special Tools and Equipment .
• J 26900-6 Dial Caliper. See Special Tools and Equipment .
• J 7872 Magnetic Base Indicator Set. See Special Tools and Equipment .

1. Apply J 36850  to the underdrive sun gear inner thrust bearing (1).
2. Install the underdrive sun gear into the underdrive thrust bearing. Install the assembly into the underdrive clutch drum (2).
   Fig 1: Installing Underdrive Sun Gear Inner Thrust Bearing

   Courtesy of GENERAL MOTORS CORP.
3. Install the underdrive sun gear into the underdrive clutch drum (2).
4. Align the inner teeth of the underdrive clutch discs.
   Fig 2: Installing Underdrive Sun Gear

   Courtesy of GENERAL MOTORS CORP.
5. Install the countershaft assembly (3) into the underdrive clutch assembly (1).
   Fig 3: Installing Countershaft Assembly Into Underdrive Clutch Assembly

   Courtesy of GENERAL MOTORS CORP.
6. Measure the countershaft assembly (1) depth using a J 26900-6  and a straight edge (A).
   • Measure the distance between the end of the countershaft and the bolt seat underdrive clutch drum support. Countershaft assembly installation depth should measure 33.3-35.5 mm (1.311-1.398 in).
   • If the countershaft assembly installation depth does not fall within specification, remove the countershaft assembly installation depth falls within specification.
7. Apply J 36850  to the countershaft driven gear thrust bearing.
   Fig 4: Measuring Countershaft Assembly Depth Using J 26900-6 & Straight Edge

   Courtesy of GENERAL MOTORS CORP.
8. Install the countershaft driven gear thrust bearing into transaxle case (1).
   Fig 5: Installing Countershaft Driven Gear Thrust Bearing

   Courtesy of GENERAL MOTORS CORP.
9. Install the countershaft driven gear (1) onto the countershaft using a J 35425  and a hammer while supporting the countershaft.
   Fig 6: Installing Countershaft Driven Gear

   Courtesy of GENERAL MOTORS CORP.
10. Install a J 8614-01  onto the countershaft locknut driven gear stationary during the countershaft locknut installation.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
11. Install the countershaft driven gear locknut onto the countershaft driven gear (1) using a J 34826  with a J 8614-01  .

    Tighten 

    1. Tighten the countershaft driven gear locknut to 177 N.m (131 lb ft).
12. Remove the J 8614-01  from the countershaft driven gear.
    Fig 7: Installing Countershaft Driven Gear Locknut Onto Countershaft Driven Gear

    Courtesy of GENERAL MOTORS CORP.
13. Measure the countershaft assembly end play using a J 7872  .
    • Place the J 7872  on the end of the countershaft assembly and gently move the countershaft up and down while observing the J 7872  .
    • The countershaft assembly (1) end play should fall within 0.2-0.9 mm (0.008-0.035 in).
    • If the countershaft assembly does not fall within specification, remove the countershaft assembly and reinstall until the countershaft assembly end play is within specification.
    Fig 8: Measuring Countershaft Assembly End Play Using J 7872

    Courtesy of GENERAL MOTORS CORP.
14. Stake the countershaft driven gear locknut (2).
    Fig 9: Staking Countershaft Driven Gear Locknut

    Courtesy of GENERAL MOTORS CORP.