Transaxle Disassemble

Tools Required

• 87-91-188  Screw Press Support. See Special Tools and Equipment .
• 87-91-204  Output Shaft Bearing Race Sleeve. See Special Tools and Equipment .
• 87-91-261  Output Shaft Remover. See Special Tools and Equipment .
• 87-91-287  Puller. See Special Tools and Equipment .
• 87-91-295  Puller Arms, 300 mm. See Special Tools and Equipment .
• 87-91-303 Puller Arms, 150 mm
• 87-91-410  Output Shaft Protector. See Special Tools and Equipment .
• 87-91-972  Assembly Ring. See Special Tools and Equipment .
• 87-92-103  Output Shaft Assembly Tool. See Special Tools and Equipment .
• 87-92-129  Lifting Eye. See Special Tools and Equipment .
• 87-92-202  Output Shaft Bearing Race Sleeve. See Special Tools and Equipment .
• J 25031-A  Three Jaw Puller. See Special Tools and Equipment .
• J 43483  Impact Driver. See Special Tools and Equipment .
• J 43707  Transaxle Support Fixture. See Special Tools and Equipment .
• J 43964  Engine Stand Fixture Adapter. See Special Tools and Equipment .

IMPORTANT: In all work involving disassembly of the transaxle, a new output shaft nut and crush sleeve must be installed during reassembly.
1. Remove the back-up lamp switch to prevent the switch from being damaged during disassembly.
Fig 1: Identifying Backup Lamp Switch
Courtesy of GENERAL MOTORS CORP.
2. Cover the holes for clutch hydraulics, axles, and the reverse lamp switch, and clean the transaxle if necessary.
3. Mount the transaxle on J 43707  . See Special Tools and Equipment . Mount the transaxle and fixture in the J 43964  . See Special Tools and Equipment .
Fig 2: Mounting Transaxle On J 43707
Courtesy of GENERAL MOTORS CORP.
4. Remove the pipe from the slave cylinder.
Fig 3: Removing Pipe From Slave Cylinder
Courtesy of GENERAL MOTORS CORP.
5. Using pliers, pinch together the bottom halves of the pipe sleeve and move the pipe and sleeve upward.
6. Pry up the locking tabs on the sleeve and remove the pipe.
Fig 4: Prying Up Locking Tabs
Courtesy of GENERAL MOTORS CORP.
7. Remove the slave cylinder bolts and slave cylinder.
Fig 5: View Of Slave Cylinder
Courtesy of GENERAL MOTORS CORP.
8. Remove the reverse idler gear shaft bolt with an O-ring.
9. Remove the transaxle rear cover and discard the gasket.
Fig 6: View Of Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Do not shift gears using the 1st/2nd, 3rd/4th, or 5th shift shafts. All shifting should be done using the shift control shaft.
10. Put the transaxle into 3rd gear by pulling the shift control shaft out. Other gears can be selected as follows:
    • Even gears = push shaft in
    • Odd gears = pull shaft out
    • 1st/2nd shift gate = turn shaft counter clockwise
    • 5th and reverse gears = turn shaft clockwise.
Fig 7: View Of Synchronizer Springs
Courtesy of GENERAL MOTORS CORP.
11. Using a punch and hammer, tap out the 5th gear fork retaining pin.
Fig 8: Locating 5th Gear Fork Retaining Pin
Courtesy of GENERAL MOTORS CORP.
12. Engage the 5th gear by pressing the synchronizer sleeve and fork down onto the 5th gear. Two gears must be engaged at the same time to allow removal of output shaft nut.
13. Pry up the locking tab on the output shaft nut and remove the nut.
Fig 9: View Of Output Shaft Nut
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Before removing the 5th gear synchronizer sleeve, mark its position relative to the 5th gear synchronizer hub to assist in assembly.
IMPORTANT: Make sure the 5th gear shift shaft does not come out of the transaxle when the 5th gear shift fork is removed.
14. Remove the 5th gear shift fork and synchronizer sleeve together.
Fig 10: View Of 5th Gear Shift Fork & Synchronizer Sleeve
Courtesy of GENERAL MOTORS CORP.
15. Remove the 5th gear synchronizer hub snap ring. This will be easier if the hub is tapped down first.
16. Use the J 25031-A  to remove the 5th gear synchronizer hub. See Special Tools and Equipment .
Fig 11: Removing 5th Gear Synchronizer Hub & Snap Ring
Courtesy of GENERAL MOTORS CORP.
17. Remove the blocking ring, blocking ring spring, 5th gear, and 5th gear bearing assembly.
18. Remove the differential bearing retainer fasteners. The retainer will be removed after case removal.
Fig 12: View Of Differential Bearing Retainer
Courtesy of GENERAL MOTORS CORP.
19. Remove the case-to-reverse idler gear shaft bracket bolt.
20. Remove the case-to-clutch housing bolts and tap down 2 case-to-clutch housing alignment sleeves.
Fig 13: View Of Case-To-Clutch Housing Bolts
Courtesy of GENERAL MOTORS CORP.
21. Remove the case from the output shaft.
    1. Check that 3rd gear is engaged.
    2. Install the 87-92-129  to the case. See Special Tools and Equipment .
    3. Install the 87-91-410  to the output shaft. See Special Tools and Equipment .
    4. Install the 87-91-287  with the 87-91-303 into the pulling eyes. See Special Tools and Equipment .
    5. Carefully tighten the puller until the output shaft bearing and 5th driven gear releases from the output shaft.
Fig 14: Removing Case From Output Shaft
Courtesy of GENERAL MOTORS CORP.
22. Remove tools. Lift off transaxle case.
23. Remove differential bearing retainer from transaxle case.
Fig 15: Locating Differential Bearing Retainer
Courtesy of GENERAL MOTORS CORP.
24. Inspect the O-ring seal and axle seal for damage. Replace if damaged.
IMPORTANT: Do not re-install the bearing race until after the shimming procedure.
25. Tap out differential bearing race using 87-92-202  and 87-91-204  . See Special Tools and Equipment .
Fig 16: View Of 87-92-202 & 87-91-204
Courtesy of GENERAL MOTORS CORP.
26. Remove the reverse gear fork and shaft.
Fig 17: View Of Reverse Gear Fork & Shaft
Courtesy of GENERAL MOTORS CORP.
27. Put the transaxle in 4th gear by pushing the shift control shaft in.
28. Remove the reverse shift lever assembly and bolts.
Fig 18: View Of Reverse Shift Lever Assembly
Courtesy of GENERAL MOTORS CORP.
29. Disengage the reverse on the shift linkage assembly. Remove the remaining shift linkage bolt and lift the mechanism slightly. Remove the locating sleeves.
30. Put the transaxle in 2nd gear and remove the shift linkage assembly by moving it rearward, towards the differential, and angling it out while lifting.
Fig 19: View Of Shift Linkage Assembly
Courtesy of GENERAL MOTORS CORP.
31. Install the reverse idler gear shaft bracket bolt finger tight.
32. Lift the input shaft far enough to allow removal of the reverse idler gear shaft assembly. Remove the reverse idler gear shaft.
Fig 20: View Of Reverse Idler Gear Shaft Assembly
Courtesy of GENERAL MOTORS CORP.
33. Remove the 4th driven gear, crush sleeve, and spacer sleeve from the output shaft.
Fig 21: View Of 4th Driven Gear, Crush Sleeve & Spacer Sleeve
Courtesy of GENERAL MOTORS CORP.
34. Install the 87-92-103  around the 1st gear and 1st/2nd gear synchronizer sleeve as shown. See Special Tools and Equipment . This tool holds the 1st and 2nd synchronizer assemblies together. Secure the tool with a plastic tie.
Fig 22: Installing 87-92-103
Courtesy of GENERAL MOTORS CORP.
35. Install the 87-91-410  on the output shaft. See Special Tools and Equipment .
36. Install the 87-91-287  with the 87-91-295  under the 1st driven gear of the output shaft. See Special Tools and Equipment .
37. Carefully tighten the puller until the remaining output shaft gears are up far enough to allow the removal of the input shaft, approximately 15 mm (0.6 in).
38. Remove the input shaft.
Fig 23: Removing Input Shaft
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Note the up/down orientation of the 3rd driven gear. If the old gear is installed, it must be installed in the same orientation to avoid noise concerns.
39. Continue pulling the driven gears on the output shaft until all gears are loose.
40. Remove the puller and gears from the output shaft.
Fig 24: Removing Puller & Gears From Output Shaft
Courtesy of GENERAL MOTORS CORP.
NOTE: The output shaft bearing retainer bolts were installed using a threadlocker at the factory. A J43483 impact driver or equivalent must be used to remove these bolts or the bolt heads may strip out requiring additional repair time.
41. Remove the output shaft bearing retainer bolts using the J 43483  or equivalent and remove the retainer. See Special Tools and Equipment .
Fig 25: Removing Output Shaft Bearing Retainer Bolts
Courtesy of GENERAL MOTORS CORP.
42. Remove the output shaft using the 87-91-188  , the 87-91-972  , and the 87-91-261  . See Special Tools and Equipment .
Fig 26: Removing Output Shaft
Courtesy of GENERAL MOTORS CORP.
43. Remove the differential assembly.
Fig 27: View Of Differential Assembly
Courtesy of GENERAL MOTORS CORP.