Transmission Assemble. Chevrolet Export Chevy P42 Commercial Chassis 1999

For 1990-2009 cars

## Transmission Assemble NV4500

### Assembly Procedure

#### Tools Required

• | J 22828 Countershaft Bearing and Input Shaft Bearing Installer

• | J 38805 Output Shaft Nut Socket

• | J 38856 Countershaft Bearing Cone and Retainer Installer

• | J 39314 Vibration Damper Installer

1. Install the following parts:

1.1. | The 5th speed gear shift lever

1.2. | The shift lever shaft (The notches that retain the 5th speed gear shift fork are to the outside of the case.)

1.3. | The shift lever retaining pin

2. Install a rubber band in order to hold the 5th speed gear shift lever back out of the way.
3. Install the countershaft front bearing cup. Use the J 38856 .
4. Install the countershaft assembly into the transmission case.
5. Install the countershaft rear bearing. Raise and support the countershaft assembly. Install a wood block between the front of the countershaft and the transmission case. Use the J 22828 .
6. Install the following parts:

6.1. | The reverse idler gear

6.2. | The bearings

6.3. | The spacer

6.4. | The washers

6.5. | The reverse idler gear shaft

7. Install the countershaft rear bearing cup.
8. Install the countershaft shim(s) and the bearing retainer plate.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

9. Measure the countershaft end play. Use the fallowing procedure:

9.1. | Set the dial indicator up on the end of the countershaft.

9.2. | Use a screwdriver or the equivalent to lift the countershaft up and down in order to measure the end play.

9.3. | The countershaft end play should be 0.05-0.15 mm (0.002-0.006 in). Add or remove shim(s) under the bearing retainer plate in order to adjust.

9.4. | Remove the retainer plate bolts.

10. Apply sealant to the bolt threads. Use Loctite™ or Dri-Loc™ 201 or the equivalent.
11. Install the countershaft shim(s) and the bearing retainer plate.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).

12. Install the countershaft bearing cap. When properly installed, the outer lip of the cap will be flush with case. Use the J 38856 .
13. Install the mainshaft assembly into the transmission case.
14. Install the main drive gear bearing and the main drive gear assembly into the transmission case.
15. Apply sealant to the main drive gear bearing retainer mating surface. Use GM P/N 1052942 or the equivalent. Do not seal off the oil hole.
16. Install the main drive gear bearing retainer. Position the retainer with the oil hole at the top-center position. Install the main drive gear bearing retainer bolts.

Tighten

1. Tighten the main drive gear bearing retainer bolts to 31 N·m (23 lb ft).
2. Tighten the mainshaft bearing retainer plate bolts to 35 N·m (26 lb ft).

17. Install the following parts:

17.1. | The mainshaft rear bearing cup

17.2. | The shim(s)

17.3. | The bearing retainer plate

17.4. | The mainshaft bearing retainer plate bolts

Tighten
Tighten the bolts finger tight only.

18. Measure the mainshaft end play using the following procedure:

18.1. | Set the dial indicator up on the end of the mainshaft.

18.2. | Use a screwdriver or the equivalent to lift the mainshaft up and down to measure the end play.

18.3. | The mainshaft end play should be 0.05-0.15 mm (0.002-0.006 in). Add or remove shim(s) under mainshaft bearing retainer plate in order to adjust.

18.4. | Remove the mainshaft bearing retainer plate bolts.

19. Apply sealant to the bolt threads.

Use Loctite® or Dri-Loc® 201 or the equivalent.

20. Install the mainshaft bearing retainer plate bolts.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).

21. Install the following parts:

21.1. | The countershaft thrust washer retainer pin

21.2. | The countershaft thrust washer

21.3. | The 5th speed gear bearings

21.4. | The spacer

22. Install the 5th speed gear assembly onto the 5th speed shift shaft and the countershaft. Slide 5th speed gear fork and the 5th speed gear assembly onto the shift shaft.
23. Install the 5th speed gear clutch gear retainer ring.
24. Install the 5th speed gear shift fork roll pins. Support the fork and drive the roll pins downward from the top of the fork.
25. (4WD models) Install the vibration damper to the mainshaft . Move the synchronizer sleeves to lock the transmission into two gears at once. Use the J 39314 .
26. (4WD models) Install the mainshaft washer and nut. Use the J 38805 .

Tighten
Tighten the mainshaft nut to 441 N·m (325 lb ft).

27. (4WD models) Install the rear oil retainer to the transmission case .

Tighten
Tighten the bolts to 54 N·m (40 lb ft).

28. (RWD models) Install the rear oil retainer to the transmission case.

Tighten
Tighten the bolts to 54 N·m (40 lb ft).

29. (RWD models) Install the following parts:

29.1. | The yoke assembly .

29.2. | The spline seal

29.3. | The washer

29.4. | A new nut. Shift the transmission into 1st gear to aid the tightening of the yoke nut.

Tighten
Tighten the yoke nut to 441 N·m (325 lb ft).

Important: Do not use any lubricant other than Castrol® Syntorq LT transmission fluid or the equivalent. Using other lubricants may cause transmission failure.

30. Fill the transmission with the proper amount of lubricant.
31. Apply sealer to the mating surfaces of the transmission cover. Use GM P/N 1052942 or the equivalent.
32. Install the shift cover to the transmission case.

Tighten
Tighten the bolts to 23 N·m (17 lb ft).

33. Apply sealer to the shift cover side of the shift tower isolator plate. Use GM P/N 1052942 or the equivalent.
34. Install the shift tower isolator plate to the shift cover.

Install the shift tower to the isolator plate.

Install the shift tower to shift cover bolts.

Tighten
Tighten the bolts to 6 N·m (53 lb in).