For 1990-2009 cars

1. Assemble the spring retainers to the synchronizer hub.
2. Align the scribe marks on the synchronizer hub to the marks on the synchronizer sleeve.

Assemble the synchronizer hub and the three struts to the synchronizer sleeve.

3. Assemble the main drive synchronizer stop ring to the synchronizer sleeve.
4. Install the drive sprocket to the mainshaft.
5. Install the synchronizer assembly to the mainshaft.
6. Install the synchronizer snap ring to the mainshaft.
7. Use a soft faced hammer to install the input gear and the planetary assembly to the annulus gear.
8. Place the magnet in its slot in the front case half.
9. Using special bearing installer/remover tool J 33832, install the output needle bearing in the rear case half.
10. Place the seal in the input bearing retainer.
11. Place the seal in the mainshaft extension housing.
12. Using special bearing installer/remover tool J 33832, install the front output bearing in the front case half.
13. Place the front output shaft seal in the front case half.
14. Using special bearing installer/remover tool J 33832, install the mainshaft pilot bearing in the input gear.
15. Using special bearing installer/remover tool J 33832, install the two drive pocket bearings in the drive sprocket.
16. Place the snap ring onto the input gear.
17. Place the forward thrust washer and carrier lock ring onto the input bearing.
18. Using special bearing installer/remover tool J 33832, install the input bearing onto the input gear.
19. Install the snap ring to the input bearing.
20. Apply RTV, GM P/N 12345739 or equivalent, to the bearing retainer mating surfaces.
21. Apply threadlocker, GM P/N 12345382 or equivalent, on the bearing retainer bolts.

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.

22. Install the input bearing retainer and the input bearing retainer bolts to the front case half.

Tighten
Tighten the input bearing retainer bolts to 19 N·m (14 lb ft).

23. Install the shift lever O-ring seal and the plastic washer to the front case half.
24. Install the selector with the shaft into the front case half.
25. Install the following components to the front case half:

• | The shift lever

• | The washer

• | The nut

Tighten
Tighten the shift lever nut to 27 N·m (20 lb ft).

26. Rotate the selector in order to align the range shift fork.

Install the range shift hub and the range shift fork into the front case half.

27. Install the front output shaft to the front case half.
28. Slide the synchronizer assembly onto the mainshaft.
29. Install the synchronizer snap ring onto the mainshaft.
30. Install the driven sprocket to the chain.

Important: The mainshaft assembly, the driven sprocket and the drive chain are installed into the front case half as an assembly.

31. Install the drive chain onto the drive sprocket, which is located on the mainshaft. Note the location on the drive chain master link.
32. Install the driven gear snap ring to the front output shaft.
33. Install the mode shift fork onto the shift rail.
34. Install the mode shift fork assembly as follows:

• | Onto the synchronizer sleeve

• | Through the range shift fork

• | Into the front case half

35. Install the mode shift fork spring to the shift rail.
36. Install the following components into the rear case half:

• | The oil pump pickup tube

• | The oil tube connector

• | The pump pickup screen

37. Install the oil tube O-ring into the oil pump.
38. Lubricate the oil pump pickup tube with automatic transmission fluid.

Install the oil pump to the oil pump pickup tube.

39. Wipe the front case half mating surfaces clean.

Apply RTV GM P/N 12345739 or equivalent to the case mating surfaces.

40. Install the dowels into the front case half.
41. Install the rear case half over the mainshaft and onto the front case.

Do not damage the oil pump while installing the rear case half.

42. Apply threadlocker GM P/N 12345382 or equivalent to the case bolts.

Install the case half bolts into the case halves. Install the two longer case bolts and washers into the doweled case holes.

Tighten
Tighten the case bolts to 31 N·m (23 lb ft).

43. Install the snap ring behind the speedometer tone wheel to the mainshaft.
44. Install the speedometer tone wheel onto the mainshaft.
45. Install the snap ring in front of the speedometer tone wheel.
46. Apply threadlocker GM P/N 12345382 or equivalent to the rear retaining housing bolts.

Install the rear retainer housing and the rear retainer bolts to the rear case half. (The rear retaining housing bolts are shouldered.)

Tighten
Tighten the rear retainer housing bolts to 41 N·m (30 lb ft).

47. Install a new output shaft bearing snap ring to the mainshaft.
48. Apply RTV GM P/N 12345739 or equivalent to the rear retainer housing mating surfaces.

Apply threadlocker GM P/N 12345382 or equivalent to the extension housing bolts.

Install the rear extension housing and extension bolts to the rear retainer housing.

Tighten
Tighten the bolts to 31 N·m (23 lb ft).