chevrolet truck Light Duty Truck 1994 Series, Repair Manual

Page: 832 / 919

UNIT ASSEMBLY
Use new seals, gaskets, and thread sealer on all bolt
threads when assembling the transmission. Tighten all
bolts to specified torque.
Lubricate all assemblies as they are installed in the
transmission using Dexron® HE automatic transmission
fluid oil or equivalent.
DRIVE GEAR ASSEMBLY
Disassemble (Figure 19)
❖
Tools Required:
J 22912-01 Bearing and Gear Puller
J 6133-01 Installer
1. Bearing (99) onto the drive gear (100) using
J 22912-01 with J 6133-01 and a press.
• Coat roller bearings and drive gear bearing bore
with lightweight grease.
2. Roller bearings (101) into the bore of the drive
gear.
3. Thrust bearing (29) and race (30) into the drive
gear.
M A IN SH A FT ASSEMBLY
Disassemble (Figures 1 and 2)
❖
Tool Required:
J 25234 Front and Rear Bearing Installer
J 37360 Spiral Snap Ring Installer
J 37372 Synchronizer and Gear Installer
Important
• If replacing first-second or third-fourth synchronizer
blocker rings, soak new blocker ring assemblies for
10 minutes in Dexron® HE or equivalent before
assembly on mainshaft.
• Coat mainshaft and gear bores with transmis­
sion lubricant.
1. First-second synchronizer sleeve (16) on mainshaft
hub.
• Align marks made during disassembly.
Important
4. Locating pin (46) into the main shaft (14).
5. Sleeve (20) and needle bearing (21) into mainshaft,
aligning notch in sleeve with locating pin.
6. First gear (22).
• Align slots in first gear with tabs on blocker ring
assembly.
7. Rear mainshaft bearing (23) with taper facing rear
of shaft.
8. Fifth gear (25) onto mainshaft (14) using J 25234
and a press.
• Lubricate fifth-gear splines with petroleum jelly.
• Carefully align the mainshaft and gear splines.
If splines are improperly aligned, damage could
occur when the gear is pressed onto the main­
shaft.
9. Fifth gear snap ring.
10. Three-piece second gear blocker ring assembly
and thrust washer (44).
11. Spiral snap ring (43) using J 37360.
12. Second gear spacer (42), needle bearing (41), and
gear (40).
• Align slots in second gear with tabs on blocker
ring assembly.
13. Second gear thrust washer (39) and snap ring (38).
14. Third gear spacer (37) and needle bearing assem­
bly (36).
• Make sure the bearing spacer is not trapped
between the gear face and snap ring. The spac­
er runs inside the gear bore.
15. Third-fourth synchronizer, third blocker ring (31),
sleeve (34), hub (32), and third gear (35) as an
assembly using J 37372 and a press.
16. Thrust bearing (29) and race (30) to front front end
of mainshaft.
Important
• Before pressing components together, make sure
the synchronizer hub faces the short end of the
mainshaft. Hold third gear against the synchronizer
to maintain blocker ring alignment with keys.
TR A N SM ISSIO N ASSEMBLY
+<■ Install or Connect (Figures 1 and 2)
• Use care in synchronizer spring placement. If syn­
chronizer is assembled with improper spring place­
ment, hard shifting will result.
2. First-second synchronizer keys (45) and springs
(15).
• Engage tang end of each spring in the same
synchronizer key, but position open end of
springs opposite of each other.
NOTICE: F o r s te p s 5, 17, 20, 23, 29, 30, a n d
32, re fe r to “ N o tic e ” on p a g e 7B3-1.
Tools Required:
J 3 7 3 5 7 C o u n te rs h a ft B e a rin g and R ace
Remover and Installer
J 8092 Universal Driver Handle
J 37372 Synchronizer and Gear Installer
J 8001 Dial Indicator