GMC S Series 1994, Repair Manual

Page: 833 / 919

1. Countershaft (52) into case (67).
2. Rear countershaft bearing (51) to countershaft
using J 37372 and a press (figure 34).
• Support the countershaft with J 37357.
Important
• Failure to properly support the countershaft may
result in permanent distortion of the case during
installation.
3. Rear countershaft bearing race (53).
4. Reverse idler gear (70) and the shaft (72).
• Hold the gear in the case with the shift lever
groove to the rear.
• Install the reverse idler shaft from the rear.
• Install a new retaining pin (71).
5. Countershaft retainer (55) to transmission housing
without shims.
Tighten
•C ountershaft retainer bolts to 20 N-m (15 lbs.
ft.).
Measure
• C ountershaft end play using dial indicator
J 8001 (figure 35).
• Remove retainer and install shim(s) as neces­
sary to provide proper end play. Zero end play
with no preload is ideal, but up to 0.10 mm
(0.004 inch) end play is allowable. Do not
preload bearing with shim(s) larger than original
end play measurement.
• Reinstall retainer (55) and bolts (56).
Tighten
• Retainer bolts (56) to 20 N-m (15 lbs. ft.).
• Bend tabs over the four attaching bolts.
6. Reverse shift fork in the case.
7. Mainshaft (14) into the transmission case.
8. Rear mainshaft bearing race (24).
9. Drive drive gear in case (100).
• Make sure rollers, thrust bearing, and washer
are in place.
• Be sure to engage the third-fourth synchronizer
sleeve and blocker ring.
10. Front bearing race (99) in the front bearing retainer
(96).
• Do not install shims in front bearing retainer at
this time.
11. Temporarily install front bearing retainer (96).
• Be sure to align the marks made during disas­
sembly.
12. Fifth gear (57) on countershaft.
• Slide shift rail and fifth gear shift fork assembly
into case.
• Align reverse shift fork and slide rail (75)
through fork.
• Position lever return spring in case with long
end of spring to the rear, and slide rail through
the spring (68).
13. Blocker ring (58) and fifth gear synchronizer (62) in
fifth gear shift fork (73).
• Slide fork rail assembly and synchronizer into
position.
14. Fifth gear synchronizer retainer (63) and snap ring
(64) (figure 8).
15. Oiling funnel (65) into rear of countershaft (figure
5).
16. Fifth gear and reverse shift lever (77) in the case
(figure 6).
• Make sure reverse shift fork pin and fifth-gear
shift rail pin are engaged with shift lever.
17. Fifth gear and reverse lever pivot bolt (78) and
retaining clip (76).
• Coat pivot bolt threads with pipe sealant GM
P/N 1052080 or equivalent.
£
Tighten
ft.).
• Pivot bolt (76) to 27 N-m (20 lbs.
18. Backup lamp switch (79).
• Coat threads with pipe thread sealant GM P/N
1052080 or equivalent.