Countershaft Assembly Installation

Tools Required

• J 36850  Transjel® Lubricant
• J 8614-01  Countershaft Driven Gear Holder
• J 35425  Rack Seal and Bearing Installer. See Special Tools .
• J 34826  Hub Nut Socket - 36 mm. See Special Tools .
• J 26900-6  Dial Caliper. See Special Tools .
• J 7872  Magnetic Base Indicator Set. See Special Tools .

1. Apply J 36850  to the underdrive sun gear inner thrust bearing (1).
Fig 1: Identifying Underdrive Clutch Drum
Courtesy of GENERAL MOTORS CORP.
2. Install the underdrive sun gear into the underdrive thrust bearing. Install the assembly into the underdrive clutch drum (2).
Fig 2: View Of Underdrive Sun Gear
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 3: Locating Countershaft Assembly
Courtesy of GENERAL MOTORS CORP.
5. Install the countershaft assembly (3) into the underdrive clutch assembly (1).
Fig 4: Measuring Countershaft Assembly With J 26900-6 & Straight Edge
Courtesy of GENERAL MOTORS CORP.
6. Measure the countershaft assembly (1) depth using a J 26900-6  and a straight edge (A). See Special Tools .
   • Measure the distance between the end of the countershaft and the bolt seat underdrive clutch drum support. Countershaft assembly installation depth should measure 30.3-32.5 mm (1.193-1.280 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 5: Countershaft Driven Gear Thrust Bearing & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
8. Install the countershaft driven gear thrust bearing into transaxle case (1).
Fig 6: Identifying J 35425
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9. Install the countershaft driven gear (1) onto the countershaft using a J 35425  and a hammer while supporting the countershaft. See Special Tools .
Fig 7: View Of J 8614-01
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 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  . See Special Tools .

    Tighten:  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 8: View Of J 7872
Courtesy of GENERAL MOTORS CORP.
13. Measure the countershaft assembly end play using a J 7872  . See Special Tools .
    • Place the J 7872  on the end of the countershaft assembly and gently move the countershaft up and down while observing the J 7872  . See Special Tools .
    • 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 9: Unstaking & Staking Countershaft Driven Gear Locknut
Courtesy of GENERAL MOTORS CORP.
14. Stake the countershaft driven gear locknut (2).