Gearshift and Select Shaft Assembly Replacement. Geo Tracker - 4WD 1997

For 1990-2009 cars

#### Tools Required

J 36850 Transjel® Transmission Assembly Lubricant

### Removal Procedure

1. Remove the gearshift control lever from the gearshift lever case. Refer to Gearshift Control Lever Replacement .
2. Remove the transfer case gearshift control lever from the transfer case. Refer to Transfer Case Assembly in Transfer Case.
3. Remove four bolts from the fan shroud at the radiator.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Place a drain pan or suitable container underneath the transmission.
6. Remove the transmission oil level/filler plug (2) from the transmission.
7. Remove the transmission drain plug (3) from the transmission and drain the transmission oil.
8. Place index marks on the propeller shaft pinion flange yoke and the differential pinion flange to ensure correct installation.
9. Remove the following items from the vehicle:

• | Four bolts

• | Four nuts

• | The rear propeller shaft

10. Remove the speedometer cable (3) from the speedometer driven gear case.
11. Remove the following items from the driven speedometer gear case.

• | One bolt (2)

• | The ground wire (1)

12. Temporarily install the speedometer driven gear case retaining bolt.
13. Remove the Three-Way Catalytic Converter (TWC) and the muffler/tail pipe assembly from the vehicle.
14. Remove the drain pan from underneath the transmission.
15. Support the transmission with a suitable hydraulic jack.
16. Remove two bolts (2) from the rear transmission mount.
17. Remove four bolts and the rear transmission crossmember from the vehicle.
18. Place a wooden block, H = 200 mm (8 in), W = 100-150 mm (4-6 in), T = 45 mm (1.8 in), between the distributor gear housing and the bulkhead (2) in order to prevent the distributor and other components from being damaged when the transmission is lowered.
19. Lower the transmission slowly until the engine contacts its support on the wood block.
20. Remove one clamp and the breather hose from the gearshift lever case.
21. Remove ten bolts and the gearshift lever case from the extension case.

### Disassemble Procedure

Refer to Transfer Case Assembly in Transfer Case for 4WD components.

1. Remove one inner and outer roll pin (9) and the gearshift arm (8) from the gearshift shaft (14).
2. Remove the gearshift control lever bushing (7) from the gearshift arm (8).
3. Remove the one roll pin (9) from the gearshift shaft (14) releasing tension on the gearshift limit spring (12).
4. Remove the one inner and outer roll pin (9) from the gearshift lever (13).
5. Remove the one roll pin (9) from the reverse gearshift limit yoke (11).
6. Unstake the gearshift lever case plug (15).
7. Remove the gearshift lever case plug (11) from the gearshift lever case (1).

Important: The gearshift lever case contains an inner and outer select return spring on the left side only. The right side contains a single select return spring. Note the location of these springs to ensure correct assembly.

8. Remove the gearshift shaft (14) from the gearshift lever case (1) while simultaneously removing the gearshift lever (13), gearshift reverse gearshift limit yoke (11) and the gearshift limit spring from the gearshift shaft (14).
9. Remove the reverse gearshift limit bolt (16) from the gearshift lever case (1).
10. Remove the following items from the gearshift lever case (1):

• | The two select return spring bolts (2)

• | The three select return springs (3)

• | The two select guide pins (4)

11. Remove the following items from the gearshift lever case (1):

• | The two lever locating bolts (5)

• | The two lever locating washers

12. Remove the gearshift lever case seat (3) from the gearshift lever case (1).
13. Clean all of the components thoroughly with solvent and air dry.
14. Inspect the gearshift shaft (12) by inserting into the gearshift lever case (1) and working back and forth while feeling for any binding. If the gearshift shaft (12) does not move freely in and out of the gearshift lever case, replace the gearshift lever case and the gearshift shaft.
15. Inspect the gearshift lever (8), the reverse gearshift limit yoke (10) and the gearshift arm for smooth fit and movement on the gearshift shaft (12). If any of the above components bind on the gearshift shaft (12), replace the gearshift shaft, the gearshift lever, the reverse gearshift limit yoke and the gearshift arm.
16. Inspect the gearshift limit spring for weakness or distortion. Replace as necessary.
17. Inspect the gearshift control lever bushing for excessive wear. Replace as necessary.
18. Inspect the gearshift lever case seat for excessive wear. Replace as necessary.

### Assemble Procedure

Refer to Transfer Case Assembly in Transfer Case for 4WD components.

1. Apply a thin coat of J 36850 to all components prior to assembly.
2. Install the gearshift lever case seat into the gearshift lever case.
3. Install the following items onto the gearshift lever case (1):

• | The two lever locating bolts (5)

• | The two lever locating washers

Tighten
Tighten the lever locating bolts to 20 N·m (15 lb ft).

Important: The gearshift lever case contains an inner and outer select return spring on the left side only. The right side contains a single select return spring.

4. Install the following items onto the gearshift lever case (1):

• | The two select guide pins (4)

• | The three select return springs (3)

• | The two select return spring bolts (2)

Tighten
Tighten the select return spring bolts to 32 N·m (24 lb ft).

5. Apply a thin coat of GM P/N 12346004, or equivalent, to the threaded portion of the reverse gearshift lever bolt threads.

Important: : The portion of the gearshift shaft which has been machined flat must be facing downward towards the inside of the gearshift lever case for correct installation.

6. Install the reverse gearshift lever bolt (16) into the gearshift lever case (1).

Tighten
Tighten the reverse gearshift lever bolt to 35 N·m (26 lb ft).

7. Install the gearshift shaft (14) into the gearshift lever case (1) while simultaneously installing the gearshift lever (13), reverse gearshift limit yoke (11), and gearshift limit spring onto the gearshift shaft (14).
8. Install the gearshift lever case plug (15) onto the gearshift lever case (1).
9. Stake the gearshift lever case plug (15) in two places on the gearshift lever case (1).
10. Install one roll pin (10) into the reverse gearshift limit yoke (11).
11. Install one inner and outer roll pin (10) into the gearshift lever (8).
12. Install one roll pin (10) into the gearshift shaft (14) for the gearshift limit spring.
13. Install the gearshift control lever bushing (7) into the gearshift arm (8).
14. Install one inner and outer roll pin (10) and gearshift arm 8) onto the gearshift shaft (14).
15. Attach the hooked end of the gearshift limit spring around the roll pin.

Then, wind the gearshift limit spring until the straight end can be fitted onto the groove on the reverse gearshift limit yoke.

### Installation Procedure

Refer to Transfer Case Assembly in Transfer Case for 4WD components

1. Apply the GM P/N 12346240, or equivalent, to the extension case gearshift lever case mating surface.

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.

2. Install the gearshift lever case (1) to extension case (2) with ten bolts.

Tighten
Tighten the gearshift lever case bolts to 17 N·m (12 lb ft).

3. Install the breather hose to the gearshift lever case by securing with one clamp.
4. Raise the transmission slowly until the engine is no longer in contact with the wood block between the bulkhead (2) and the distributor gear housing.
5. Remove the wood block.
6. Install the rear transmission crossmember onto the vehicle by securing with four bolts.

Tighten
Tighten the rear transmission crossmember bolts to 60 N·m (44 lb ft).

7. Install the two bolts (2) to the rear transmission mount (1).

Tighten
Tighten the rear transmission mount bolts to 60 N·m (44 lb ft).

8. Remove the hydraulic jack from underneath the transmission.
9. Install the Three-Way Catalytic Converter (TWC) and the muffler/tail pipe assembly to the vehicle.
10. Remove the speedometer driven gear case retaining bolt.
11. Install the ground wire (1) to the speedometer driven gear case by securing with one bolt.

Tighten
Tighten the speedometer driven gear case retaining bolt (2) to 12 N·m (106 lb in).

12. Install the speedometer cable (3) to speedometer driven gear case.
13. Install the rear propeller shaft into the vehicle aligning the index marks made during removal by securing with four bolts and four nuts.

Tighten
Tighten propeller shaft bolts and nuts to 50 N·m (37 lb ft).

14. Apply the GM P/N 12346004, or equivalent, to the threaded portion of the transmission drain plug.
15. Install the transmission drain plug (1) into the transmission.

Tighten
Tighten the transmission drain plug (1) to 28 N·m (20 lb ft).

16. Add approximately 1.5 liters (1.6 quarts) of synthetic 75W-90 GL4 lubricant, or equivalent, into the transmission oil level/filler plug hole. The oil level should be even with the bottom of the transmission oil level/filler plug hole.
17. Apply GM P/N 12346004, or equivalent, to the threaded portion of the transmission oil level/filler plug (2).
18. Install the transmission oil level/filler plug (3) into the transmission.

Tighten
Tighten the oil level/filler plug (3) to 28 N·m (20 lb ft).

19. Lower the vehicle.
20. Install the four bolts to the fan shroud at the radiator.

Tighten
Tighten the fan shroud bolts to 10 N·m (89 lb in).

21. Install the gearshift control lever to the gearshift lever case. Refer to Gearshift Control Lever Replacement .