For 1990-2009 cars

# M86 M94 Transmission Information to Disassemble Third Fourth and Fifth Gear

Subject: | M86 M94 Transmission Information to Disassemble Third Fourth and Fifth Gear

Models: | 2000-2005 Chevrolet Cavalier

| 2000-2004 Oldsmobile Alero

| 2000-2005 Pontiac Grand Am, Sunfire

| 2003-2006 Saturn Ion, Vue

This PI has been revised to add the 2006 Model Year. Please discard PIP3669.

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

### Condition/Concern:

When making repairs to components on the output shaft of the Getrag M86/M94 5 speed manual transaxle, some technicians are having trouble getting the third and or fourth driven gears off of or onto the output shaft. These gears are not splined to the output shaft, but are a very tight press fit.

### Recommendation/Instructions:

When pressing these gears on or off of the output shaft, care needs to be taken to ensure that the shaft is not nicked or have any burrs on it. (The shaft and gear need to be free of dirt or debris) Extreme care should be taken not to bind or cock the gear on the shaft, if this happens, press the gear back off the shaft and start over. Press loads can reach 2-3 tons on the 4th fixed gear and 12-17 tons on the 3rd fixed gear (both located on the output shaft). The 3rd and 4th speed gears (on the input shaft) come off with minimal pressure but if trying to remove the 5th fixed gear and the 3rd speed gears at the same time press loads in excess of 20 tons will not move the gear. Gears need to be removed and installed one at a time.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.