For 1990-2009 cars

### Shift Shaft Assemblies and Gear Clusters Installation

#### Tools Required

J 36850 Transjel® Assembly Lubricant.

1. Lubricate all components as assembly progresses, using J 36850 .
2. Install the input shaft (1) in the adapter plate (2).
3. Assemble the shift shaft (2) to the mainshaft (1).
4. Install the neutral return roll pin to the shift shaft (2).
5. Install the mainshaft (1) and the shift shaft (2) assembly into the adapter plate (3).
6. Install the countershaft assembly (1) to the adapter plate (3) using the following sequence:

6.1. | Lift up the mainshaft assembly (2) enough in order to install the countershaft assembly (1).

6.2. | Install the countershaft assembly (1).

6.3. | Lift the mainshaft assembly (2) enough in order to rotate the input shaft to engage the synchronizer keys with 4th gear blocking ring.

7. Install the 5th/6th and the reverse shift shaft (1).

Align the slots of the shift shaft levers (2) with the interlock plate (3).

### Reverse Lockout Assembly Assemble

Caution: Refer to General Repair Instructions in the Preface section.

1. Install the reverse lockout outer spring (5) to reverse lockout plunger (6).
2. Install the reverse lockout collar (4) to reverse lockout plunger (6).
3. Compress the reverse lockout plunger and the collar (4) in a vise and install the retainer ring (3).
4. Install the reverse lockout inner spring (2 to reverse lockout body (1)).
5. Install the reverse lockout plunger assembly in the reverse lockout body (1).
6. Install the circlip (7) to reverse lockoutbody (1).
7. Install the O-ring (8) to reverse lockout body (1).

### Transmission Case Installation

#### Tools Required

J 36850 .

Important: Lubricate all components as the assembly progresses. Use J 36850 or the equivalent.

1. Apply LOCTITE™ "Ultrablack" 598 sealant or equivalent to the transmission case to adapter plate mating surface (1).
2. Do the following in order to install the transmission case and the offset lever:

2.1. | Shift the transmission into NEUTRAL in order to keep the 3rd/4th shift shaft from engaging.

2.2. | Install the offset lever.

2.3. | Slide the transmission case onto the gear clusters and the shift rail components.

3. Apply thread sealer, LOCTITE™ 242 or equivalent to the threads of the shift lever guide bolts (1).

Notice: Refer to Fastener Notice in the Preface section.

4. Install the shift lever guide bolts (1) and pull up on 5th/6th and reverse shift rail assembly. This will help align the slot of the shift interlock plate with the guide bolt hole.

Tighten
Tighten the bolts to 27 N·m (20 Ib ft).

5. Install the adapter plate to transmission case bolts (1).

Tighten
Tighten the bolts to 48 N·m (36 Ib ft).

6. Install the magnets (1) into the transmission case (2).
7. Install the shift detent plug (1), spring (2) and ball (3).
8. Install the shift detent assembly (1).

Tighten
Tighten the detent assembly to 40 N·m (30 Ib ft).

### Countershaft Gear Installation

#### Tools Required

J 5590 Press Tube.

1. Install the spacer (3), caged needle bearing (2), and the 6th driven gear (1) to the countershaft (4).
2. Install the 5th/6th speed drive gear thrust washer (4), speed drive gear inner cone (3), speed drive gear friction cone (2) and speed drive gear synchronizer blocking ring (1).
3. Install the 5th/6th shift fork (3), synchronizer sleeve (1) and synchronizer hub (2) assembly using J 5590 (4) and a mallet.
4. Install the speed drive gear synchronizer blocking ring (4), speed drive gear friction cone (3), speed drive gear inner cone (2) and speed drive gear thrust washer (1).
5. Install the retainer clip (1) to the countershaft (2).
6. Install the spacer (1) to the countershaft (2).
7. Install the 5th/6th speed shift fork retainer ring (1).
8. Install the needle bearing (1) to the countershaft (2).
9. Install the 5th gear (1) to the countershaft (2).
10. Install the spacer (2) and the countershaft retainer (1).
11. Install the countershaft gear (1) using J 5590 (2) and a mallet.
12. Install the countershaft retainer clip (1).
13. Install the collar (2) and the reverse shift shaft pin (1).

### 5th/6th Speed Driven Gear Installation

#### Tools Required

• | J 39441 5th/6th Driven Gear Installer.

• | J 39441-10 5th Gear Installer Adapter.

Install the 5th/6th speed driven gear (3) using the J 39441 (1) and J 39441-10 (2). The smaller outside diameter (OD) of the gear faces down.

### Reverse Shift Fork Installation

1. Install the reverse shift fork (3), the synchronizer (2) and the thrust washer (1).
2. Install a new shift fork retainer ring (1).
3. Install the reverse synchronizer retainer ring (1).

### Reverse Speed Gear Installation

1. Install the reverse gear synchronizer blocking ring (6) to the mainshaft (7).
2. Install the wave washer (5) to the mainshaft (7).
3. Install the reverse gear caged needle bearing (4) to the mainshaft (7)
4. Install the reverse gear (3) to the mainshaft (7).
5. Install the reverse gear thrust washer (2) to the mainshaft (7).
6. Install the mainshaft snap ring (1) to the mainshaft (7).
7. Install the mainshaft spacer (4) to the mainshaft (5).
8. Install the mainshaft rear roller bearing (3) to the mainshaft (5).
9. Install the mainshaft spacer (2) to the mainshaft (5).
10. Install the mainshaft snap ring (1) to the mainshaft (5).
11. Install the shift shaft extension (1).
12. Install the shift guide (2).
13. Install NEW shift guide roll pins (3).

### Extension Housing Assemble

#### Tools Required

J 44395 Transmission Holding Fixture.

1. Install the countershaft oil funnel (1) to the extension housing.
2. Install the selective shims (2). Refer to Shimming Procedures .
3. Install the countershaft bearing race (3) to the extension housing.
4. Install the countershaft bearing race retaining circlip (4) to the extension housing.
5. Install the reverse idler shaft (1) to the extension housing.
6. Install the roller bearing (2) to the reverse idler shaft.
7. Install the reverse idler gear (3) to the reverse idler shaft.
8. Apply thread sealer, LOCTITE™ 242 or equivalent to the reverse idler shaft brackets bolt threads.

Notice: Refer to Fastener Notice in the Preface section.

9. Install the reverse idler shaft bracket to the extension housing.
10. Apply an approved threadlock to the reverse idler shaft brackets bolt threads.
11. Install the reverse idler shaft bracket to extension housing retaining bolts.

Tighten
Tighten the bolts to 25 N·m (18 Ib ft).

Important: DO NOT damage the reverse lockout solenoid electrical connector (3).

12. Install the reverse lockout solenoid (1) to the transmission extension housing.
13. Install the reverse lockout solenoid to transmission extension housing retaining screw (2).
14. Apply LOCTITE™ "Ultrablack" 598 sealant or equivalent to the extension housing to the transmission case mating surface (1).
15. Apply thread sealer, LOCTITE™ 242 or equivalent to the top 2 extension housing bolts.

Important: Align the 5th/6th shift shaft to the extension housing bore in order to install the extension housing.

16. Install the extension housing (2).
17. Install the extension housing bolts (1).

Tighten
Tighten the bolts to 48 N·m (36 lb ft).

18. Install the drive flange (2) to the transmission output shaft (1).
19. Install the J 45012 (3) to the drive flange (2).
20. Install the J 45012 to drive flange retaining bolts (4) and nuts (1) and tighten until firm.
21. Install the drive flange thrust washer (3).

Notice: Refer to Fastener Notice in the Preface section.

22. While holding the J 45012 (5), install the NEW flange retaining nut (2) using the J 29873 (1) to the flange (4).

Tighten
Tighten the nut to 135 N·m (100 lb ft).

23. Remove the J 45012 to drive flange retaining bolts (4) and nuts (1).
24. Remove the J 45012 (3) from the drive flange (2).
25. Install the shifter cover plate (1) to the transmission (3).
26. Install the shifter cover plate to transmission retaining bolts (2).
27. Install the transmission vent tube to the vent pipe.

Notice: Refer to Fastener Notice in the Preface section.

28. Install the transmission vent tube to transmission case retaining bolt (1).

Tighten
Tighten the transmission vent tube retaining bolt to 48 N·m (35 lb ft).

29. Remove the J 44395 .
30. Install the remaining 2 adapter plate bolts (1) and (2).

Tighten
Tighten the adapter plate bolts to 48 N·m (36 lb ft).

31. Install the concentric actuator from the transmission. Refer to Clutch Concentric Actuator Cylinder Replacement .