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Home >> Pontiac >> 2007 >> Solstice Base, Standard >> Repair and Diagnosis >> Transmission >> Manual Transmission >> Repair Instructions >> Transmission Disassemble

Transmission Disassemble

Tools Required

J 8433  Two Jaw Puller. See Special Tools .

    Fig 1: View Of Drain Plug
    GM872959Courtesy of GENERAL MOTORS CORP.
  1. Remove the drain plug, with aluminum washer, and drain the transmission fluid.
    2. Fig 2: View Of Vehicle Speed Sensor With O-Ring Seal
    GM1644159Courtesy of GENERAL MOTORS CORP.
  2. Remove the vehicle speed sensor with O-ring seal.
    3. Fig 3: View Of Backup Lamp Switch With Aluminum Washer
    GM1644162Courtesy of GENERAL MOTORS CORP.
  3. Remove the backup lamp switch, with the aluminum washer, from the front case.
    4. Fig 4: View Of Bolts Retaining Clutch Housing
    GM1644163Courtesy of GENERAL MOTORS CORP.
  4. Remove the 9 bolts retaining the clutch housing.
  5. Using a soft-face hammer, remove the clutch housing from the transmission assembly.
    6. Fig 5: View Of Output Shaft Nut, O-Ring, Flange & Dirt Deflector
    GM1847538Courtesy of GENERAL MOTORS CORP.
  6. Remove the output shaft nut.
  7. Remove the output flange.
  8. Remove the o-ring seal.
    9. Fig 6: View Of Shift Control Lever Components
    GM1644181Courtesy of GENERAL MOTORS CORP.
  9. Remove the shift control lever boot.
  10. Remove the shift control lever bolt/screw and retainer.
  11. Remove the shift control bracket screws and shift control bracket.
    12. Fig 7: Removing/Installing Shift Control Housing With New Gasket
    GM1644165Courtesy of GENERAL MOTORS CORP.
  12. Shift the transmission into NEUTRAL.
  13. Remove the shift control housing bolts.
  14. Remove the shift control housing.
  15. Remove the shift control housing gasket.
    16. Fig 8: View Of Shift Control Lever Socket Bolt
    GM1644169Courtesy of GENERAL MOTORS CORP.
  16. Remove the shift control lever socket bolt.
    17. Fig 9: View Of Extension Housing Retaining Bolts, Studs, And Brackets
    GM1644170Courtesy of GENERAL MOTORS CORP.
  17. Mark the location of the brackets and the studs.
  18. Remove the extension housing retaining bolts, studs, and brackets.
    19. Fig 10: View Of Shift Control Socket At Extension Housing Shift Lever Cavity
    GM1644171Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Machined Surface Damage Notice .
  19. Using a soft-face hammer, separate the extension housing from the intermediate case.
  20. Slide the extension housing off the shift control shaft.
  21. Remove the shift control socket from the extension housing shift lever cavity.
    22. Fig 11: Identifying Shift Control Shaft
    GM880657Courtesy of GENERAL MOTORS CORP.
  22. Remove the shift control shaft from the shift shaft gates.
    23. Fig 12: Locating Input Shaft Bearing Retainer Bolts
    GM872978Courtesy of GENERAL MOTORS CORP.
  23. Remove the front bearing retainer bolts. Discard the bolts. New bolts are required for assembly.
  24. Remove the front bearing retainer.
    25. Fig 13: Removing/Installing Input Shaft Seal
    GM872983Courtesy of GENERAL MOTORS CORP.
  25. Using a suitable punch and a hammer, remove the input shaft seal from the bearing retainer. Do not use the seal again.
    26. Fig 14: Locating Outer Retaining Rings On Input Shaft Bearing & Countershaft Front Bearing
    GM872989Courtesy of GENERAL MOTORS CORP.
  26. Remove the outer retaining ring from the input shaft bearing.
  27. Remove the outer retaining ring from the countershaft front bearing.
    28. Fig 15: Shearing Sealer On Transmission Front Case
    GM880658Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Machined Surface Damage Notice .
  28. Using a soft-face hammer on the transmission front case, shear the sealer.
  29. Remove the transmission front case from the intermediate case.
    30. Fig 16: Locating Oil Baffle Bolts
    GM880662Courtesy of GENERAL MOTORS CORP.
  30. Remove the oil baffle bolts.
  31. Remove the oil baffle.
    32. Fig 17: View Of Transmission Magnet
    GM880663Courtesy of GENERAL MOTORS CORP.
  32. Remove the magnet.
    33. Fig 18: Installing Intermediate Case Temporary Mounting Bolts
    GM880665Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Machined Surface Damage Notice .
  33. Install 2 bolts, with nuts, in the lower holes of the intermediate case. The bolts will be used to hold the intermediate case in a vise during disassembly and assembly.
    34. Fig 19: Measuring Axial Clearance On 5th Synchronizer Gear
    GM881213Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Before removal of the 5th synchronizer gear, measure the axial play of the speed gear. Incorrect axial play of the gear may cause shifting concerns or transmission noise.
  34. Using a feeler gage between the 5th countershaft gear and the thrust washer, measure the axial clearance.

    Specification: 

    • Standard Clearance: 0.10-0.35 mm (0.0039-0.0138 in)
    • Maximum Clearance: 0.40 mm (0.0157 in)

  35. If the clearance exceeds the maximum, refer to Gears and Shafts Cleaning and Inspection .
    36. Fig 20: Removing/Installing 5th Synchronizer Gear Retaining Ring
    GM880666Courtesy of GENERAL MOTORS CORP.
  36. Mount the intermediate case assembly in a vise on the 2 previously installed bolts.
  37. Using 2 screwdrivers and a hammer, remove the 5th synchronizer gear retaining ring.
    38. Fig 21: Removing 5th Synchronizer Gear Using J 8433
    GM880668Courtesy of GENERAL MOTORS CORP.
  38. Using J 8433  with 2 bolts in the threaded holes of the 5th synchronizer gear, remove the gear. See Special Tools .
    39. Fig 22: View Of 5th/Reverse Gear Synchronizer
    GM1526787Courtesy of GENERAL MOTORS CORP.
  39. Remove the 5th/reverse gear synchronizer.
    40. Fig 23: Removing/Installing 5th Shift Fork Roll Pin
    GM1526791Courtesy of GENERAL MOTORS CORP.
  40. Using a hammer and a punch, remove the 5th shift fork roll pin.
    41. Fig 24: View Of 5th/Reverse Synchronizer Assembly & 5th Countershaft Gear Bearing
    GM1526793Courtesy of GENERAL MOTORS CORP.
  41. Remove the shift fork, the 5th/reverse synchronizer sleeve and blocking ring assembly and the 5th countershaft gear and bearing.
    42. Fig 25: Locating 5th Gear Thrust Washer
    GM880678Courtesy of GENERAL MOTORS CORP.
  42. Remove the 5th countershaft gear thrust washer.
  43. Remove the thrust washer lock pin.
    44. Fig 26: Identifying Rear Bearing Retainer & Retaining Bolts
    GM880680Courtesy of GENERAL MOTORS CORP.
  44. Remove the bolts for the rear bearing retainer.
  45. Remove the rear bearing retainer.
    46. Fig 27: Identifying Outer Retaining Ring On The Countershaft Rear Bearing
    GM880682Courtesy of GENERAL MOTORS CORP.
  46. Using a soft-face hammer, tap the countershaft rearward to expose the outer retaining ring on the countershaft rear bearing.
  47. Using a suitable prying tool on the retaining ring, remove the countershaft rear bearing. The bearing will slide out of the case if the countershaft is kept in position with the output shaft.
    48. Fig 28: View Of Countershaft
    GM880684Courtesy of GENERAL MOTORS CORP.
  48. Remove the countershaft.
    49. Fig 29: Locating Reverse Gear Idler Shaft And Reverse Idler Gear
    GM880685Courtesy of GENERAL MOTORS CORP.
  49. Remove the reverse idler gear shaft and reverse idler gear.
    50. Fig 30: View Of Input Shaft Assembly
    GM880686Courtesy of GENERAL MOTORS CORP.
  50. Remove the input shaft assembly, with the 4th gear blocking ring, and output shaft front support bearing from the output shaft.
    51. Fig 31: Identifying Shift Fork Bolts
    GM880688Courtesy of GENERAL MOTORS CORP.
  51. Remove the 1st/2nd shift fork bolt.
  52. Remove the 3rd/4th shift fork bolt.
    53. Fig 32: Locating Retaining Ring For The Reverse Shift Lever
    GM880690Courtesy of GENERAL MOTORS CORP.
  53. Remove the retaining ring for the reverse shift lever on the reverse shift shaft.
    • Use a suitable pair of pliers to push the retaining ring.
    • Only push the retaining ring partially off to keep it from flying.
    • Use a pair of pliers to remove the retaining ring the rest of the way.
    54. Fig 33: View Of Retaining Ring Groove On The Reverse Shift Shaft
    GM880691Courtesy of GENERAL MOTORS CORP.
  54. Shift the reverse shift shaft forward.
  55. Move the reverse shift lever forward past the retaining ring groove on the reverse shift shaft. This allows clearance of the reverse shift fork during removal of the output shaft.
    56. Fig 34: View Of Output Shaft Rear Bearing Outer Retaining Ring
    GM880695Courtesy of GENERAL MOTORS CORP.
  56. Remove the output shaft rear bearing outer retaining ring.
    57. Fig 35: Identifying Output Shaft Assembly
    GM880697Courtesy of GENERAL MOTORS CORP.
  57. Remove the output shaft assembly.
    • Hold the 1st/2nd shift fork and the 3rd/4th shift fork in position to the output shaft.
    • Slide the 1st/2nd shift fork and the 3rd/4th shift fork off the shift shafts while removing the output shaft.
    58. Fig 36: Locating Shift Shaft Detent Plugs
    GM880698Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the shift shafts or the intermediate case do not require service, proceed to Output Shaft Disassemble. If the shift shafts or intermediate case require service, proceed to the next step.
  58. Remove the 4 shift shaft detent plugs for the shift detent balls and springs. Discard the plugs. New plugs are required for assembly.
    59. Fig 37: View Of Shift Shaft Detent Springs And Balls
    GM880699Courtesy of GENERAL MOTORS CORP.
  59. Using a magnet, remove the 1st/2nd shift shaft detent spring and ball.
  60. Using a magnet, remove the 3rd/4th shift shaft detent spring and ball.
  61. Using a magnet, remove the 5th shift shaft detent spring and ball. The reverse shift shaft does not have a detent spring and ball in the plug opening.
    62. Fig 38: Locating Shift Shaft Retaining Rings
    GM880707Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: To prevent the retaining rings from flying, cover the area with a rag.
  62. Remove the following shift shaft retaining rings:
    • The 1st/2nd shift shaft
    • The 3rd/4th shift shaft
    • The 5th shift shaft
    • Use a suitable pair of pliers to push the retaining ring.
    • Only push the retaining ring partially off to keep it from flying.
    • Use a pair of pliers to remove the retaining ring the rest of the way.
    63. Fig 39: Identifying 3rd/4th Shift Shaft
    GM880763Courtesy of GENERAL MOTORS CORP.
  63. Remove the 3rd/4th shift shaft.
    64. Fig 40: Locating 1st/2nd Shift Shaft
    GM880771Courtesy of GENERAL MOTORS CORP.
  64. Using a magnet, remove the 1st/2nd and 3rd/4th shift shaft interlock pin.
  65. Remove the 1st/2nd shift shaft.
  66. Remove the small interlock pin from the 1st/2nd shift shaft.
    67. Fig 41: View Of 5th Shift Shaft & Detent Ball
    GM880775Courtesy of GENERAL MOTORS CORP.
  67. Using a magnet, remove the 5th shift shaft and 1st/2nd shift shaft interlock pin.
  68. Remove the 5th shift shaft.
    69. Fig 42: Identifying Detent Ball In The Reverse Shift Lever
    GM880784Courtesy of GENERAL MOTORS CORP.
  69. Remove the detent ball from the reverse shift lever.
    70. Fig 43: Locating Detent Spring & Ball
    GM880787Courtesy of GENERAL MOTORS CORP.
  70. Remove the reverse shift lever, with the reverse shift fork, from the reverse shift shaft.
    1. Slide the shift lever to the end of the shaft.
    2. Cover the detent ball opening with your hand.
    3. Let the detent ball and spring land in your hand.
    71. Fig 44: Locating Reverse Gear Shift Shaft
    GM880791Courtesy of GENERAL MOTORS CORP.
  71. Using a magnet, remove the interlock pin from the reverse shift shaft. The shaft may require moving back and forth to remove the interlock pin.
  72. Remove the reverse shift shaft.
    73. Fig 45: Installing/Removing Reverse Shift Fork Bracket And Bolts
    GM880792Courtesy of GENERAL MOTORS CORP.
  73. Remove the bolts and the reverse shift fork bracket.
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