For 1990-2009 cars

#### Tools Required

• | J 37758 Countershaft Rear Plug Installer

• | J 8092 Driver Handle

• | J 36850 Transjel Transmission Assembly Lubricant

• | J 35421 Rack End Bushing Installer

• | J 8614-01 Countershaft Driven Gear Holder

• | J 34826 Hub Nut Socket

• | J 35552 Differential Side Bearing Cup Installer

1. Install the countershaft drive gear outer race (2) into the transaxle case (1) using a J 37758 with a J 8092 and a hydraulic press.
2. Install the countershaft drive gear outer race snap ring (1) onto the countershaft drive gear outer race (2).
3. Install the new crush sleeve onto the countershaft drive gear.
4. Apply J 36850 to the countershaft drive gear and outer bearings.
5. Install the countershaft drive gear into the transaxle case using a J 35552 with a J 8092 and a hydraulic press.
6. Install the countershaft drive gear inner bearing into the countershaft drive gear outer race.
7. Install the intermediate shaft (2) into the transaxle case (1) and into the countershaft drive gear.
8. Install a J 8614-01 onto the countershaft driven gear stationary during intermediate shaft locknut installation.

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. Install the intermediate shaft locknut onto the intermediate shaft using a J 34826 .

Tighten
Tighten the intermediate shaft locknut to 177 N·m (131 lb ft).

10. Remove the J 8614-01 from the countershaft driven gear.
11. Stake the intermediate shaft locknut.
12. Inspect the intermediate shaft (1) for smooth rotation.
13. If the intermediate shaft does not rotate smoothly, remove the countershaft drive gear bearings and inspect for excessive wear or damage.
14. Clean the sealant from the rear case cover mating surfaces on the rear case cover and transaxle case (2).
15. Apply the RTV silicone sealer GM P/N 1052917, or equivalent, to the rear case cover mating surface.

Important: Eleven of the 13 rear case cover bolts are 25 mm (0.984 in) in length. The two remaining bolts are 32 mm (1.259 in) in length. Verify that the two longer bolts are installed in their correct position.

16. Install the rear case cover (1) to the transaxle case. Secure the assembly with thirteen bolts.

Tighten
Tighten the rear case bolts to 10 N·m (89 lb in).