SECTION 7B3 - MANUAL TRANSMISSION - GEN III V8 ENGINE

Transcription

1 SECTION 7B3 - MANUAL TRANSMISSION - GEN III V8 ENGINE CAUTION: This vehicle will be equipped with a Supplemental Restraint System (SRS). An SRS will consist of either seat belt pre-tensioners and a driver's side air bag, seat belt pre-tensioners and a driver's and front passenger's side air bags or seat belt pre-tensioners and a driver's and front passenger's side air bags. Refer to SAFETY PRECAUTIONS, Section 12M Supplemental Restraint System, of this Service Information CD before performing any service operation on or around any SRS components, the steering mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could result in SRS deployment, resulting in possible personal injury or unnecessary SRS system repairs. CAUTION: Whenever any component that forms part of the ABS or ABS/ETC (if fitted), is disturbed during Service Operations, it is vital that the complete ABS or ABS/ETC system is checked, using the procedure as detailed in 4. DIAGNOSIS, ABS or ABS/ETC FUNCTION CHECK, in Section 12L ABS & ABS/ETC, VT Series I Service Information (V6 Engine) or VT Series II Service Information (GEN III V8 Engine) of this Service Information CD. 1. GENERAL INFORMATION With the introduction of the GEN III V8 engine, the manual transmission available for fitment to this engine, is the six speed, Tremec, Type T56 (production option MM6). This manual transmission is optional equipment on GEN III V8 engined Executive models and Berlina. The T56 manual transmission is a fully synchronised unit, including reverse gear, with blocking ring type synchronisers. The transmission primarily consists of a four piece construction comprising a clutch housing bolted to a front adaptor plate, transmission case and extension housing. During disassembly, the major number of gear train components and shift mechanism remain on the transmission front adaptor plate.

2 1.1 GENERAL DESCRIPTION SYNCHRONISER ASSEMBLIES Each of the four synchroniser hubs are splined to their respective shafts and secured by a snap ring. All synchromesh blocking rings have a carbon fibre frictional material and are brass, except for 1st and 2nd gears. The blocking rings used on 1st and 2nd gears are of a double cone construction, with carbon fibre frictional material on each side of the inner member. The purpose of the synchroniser assemblies is to permit clutching to the required gear. Synchroniser Action During synchroniser operation, the synchroniser ring is moved into engagement by the appropriate fork, carrying with it, three spring loaded synchroniser inserts, located in slots in the synchroniser hub. The synchroniser ring, together with the inserts, is moved along the hub, placing a load on the three lugs of the blocking ring. This initial force is sufficient to seat the blocking ring and start pre-synchronisation because of the friction between the cone on the constant mesh gear and the blocking ring. At this stage, gear engagement is prevented as long as there is a difference in speed between the mating surfaces of the blocking ring and cone of the constant mesh gear. As the speeds between the blocking ring and the gear cone become synchronised, the teeth on the blocking ring and gear cone line up with the internal splines of the ring, allowing the ring to engage the teeth on the gear being engaged, completing gear selection. REVERSE GEAR The reverse idler gear is in constant mesh with the counter gear extension and the reverse gear, splined to the mainshaft. When reverse gear is engaged, the reverse synchromesh ring engages the reverse constant mesh gear, completing the selection. BEARING SUPPORT All shafts in the transmission are supported by taper roller bearings, except for a parallel roller bearing at the rear of the mainshaft. The input shaft gear, front countershaft gear and rear countershaft gear extension bearing cups are a sliding fit in their respective housings. Selective shims are located under each of the bearing cups to control bearing pre-load or end float (for the countershaft extension). Each of the constant mesh gears is supported by caged needle roller bearings, except for the reverse idler gear that has a twin, caged needle roller bearing running on the reverse idler gear shaft. LUBRICATION Lubrication of all internal components is by splash feed, provided by the rotating countershaft gear assembly. SELECTOR MECHANISM The floor mounted, gearshift control lever operates through a remote lever arrangement onto a single rail mechanism which extends into the transmission rear case. The 1st/2nd, 3rd/4th, 5th/6th and reverse shift shaft rails are all supported at each end, in the adaptor plate, transmission case or extension housing. A shift interlock system, prevents engagement of more than one gear at a time. The system consists of a selector pin and interlock plate mounted on the 1st/2nd and 3rd/4th selector shaft rail. When any gear is selected, the selector pin is aligned with the particular shift fork link or shift lever, with 5th/6th and reverse gears. As this selector pin slides within the interlock plate, only the gear selected can be engaged.

3 REVERSE LOCKOUT MECHANISM The transmission is also fitted with a reverse lockout solenoid assembly that prevents the selection of reverse gear, above road speeds of 8 km/h. Above this speed, the Powertrain Control Module (PCM), causes the solenoid plunger (1) to block the movement of the spring loaded, reverse lockout plunger (2) (See view B, next). When activated, the rear offset lever (3) is blocked from rotating to the reverse selection position. SHIFT PATTERN The shift pattern is as shown in Figure 7B3-2. Point A indicates that reverse gear can be inhibited by the reverse lockout solenoid assembly, just described. Figure 7B3-1 - Reverse Lockout Mechanism Refer Figure 7B3-3 for a sectioned view of the type T56 transmission (production option MM6) and Figure 7B3-4 for an exploded view of the transmission components. Figure 7B3-2 - Transmission Shift Pattern

4 1. Input Shaft 2. Input Shaft Drive Gear 3. Third Speed Driven Gear 4. Second Speed Driven Gear 5. First Speed Driven Gear 6. Reverse Driven Gear 7. Fifth Speed Drive Gear 8. Sixth Speed Drive Gear 9. Mainshaft 10. 5th/6th Speed Compound Gear 11. Countershaft Gear 12. Countershaft Gear Extension 13. Reverse Idler Gear Figure 7B3-3 - Type T56 Transmission, Sectioned View

5 Figure 7B3-4 - Transmission Components

6 REF No. PART NAME REF No. PART NAME REF No. PART NAME Plate, Transmission Adaptor Plug Pin, Dowel (2 places) Pin, Dowel (2 places) Bushing, Shift Rail Seal, Input Shaft Shim, Input Shaft Cup, Input Shaft Bearing Bearing, Input Shaft Tapered Shaft, Input Cup, Input Shaft Bearing Blocker Ring, 4th Gear Ring, Snap Synchroniser Assembly, 3rd/4th Spring, 3rd/4th Synchroniser Key, 3rd/4th Synchroniser Hub, 3rd/4th Synchroniser Ring, 3rd/4th Synchroniser Blocker Ring, 3rd Gear Gear, 3rd Speed Bearing, 3rd Gear Needle Bearing, Mainshaft Small Tapered Mainshaft Bearing, 2nd Gear Needle Gear, 2nd Speed Washer, Thrust Cone, Inner Cone, Friction Blocker Ring, 2nd Gear Synchroniser Assembly, 1st/2nd Spring, 1st/2nd Synchroniser Key, 1st/2nd Synchroniser Hub, 1st/2nd Synchroniser Ring, 1st/2nd Synchroniser Blocker Ring, 1st Gear Cone, Friction Cone, Inner Washer, Thrust Ring, Snap Bearing, 1st Gear Needle Gear, 1st Speed Bearing, Mainshaft Large Tapered Cup, Mainshaft Bearing Case, Transmission Bolt, Shift Lever Guide Bolt, Shift Lever Guide Bolt, Shift Detent Cover Cover, Shift Detent Bushing, Shift Rail Pin, Front Offset Lever Roll Lever, Front Offset Spring, Shift Detent Ball, Shift Detent Bolt, Shift Guide Plate Plate, Shift Guide Enhancer, Shift Magnet (2 places) Pin, Dowel (2 places) Switch, Back-up Lamp Plug, Fill Gear, 5th/6th Driven Synchroniser Assembly, Reverse Spring, Reverse Synchroniser a. 95b Key, Reverse Synchroniser Hub, Reverse Synchroniser Ring, Reverse Synchroniser Retainer, Reverse Synchroniser Key Washer, Thrust Ring, Snap Blocker Ring, Reverse Gear Washer, Wave Bearing, Reverse Gear Needle Gear, Reverse Washer, Thrust Ring, Snap Spacer Bearing, Rear Mainshaft Tapered Spacer Ring, Snap Ring, Snap Ring, Speedometer Pulse Ring, Snap Ring, Sealing Ring, Snap Cup, Mainshaft Bearing Rear Housing, Transmission Extension Sensor, Electronic Speed Bolt, Speed Sensor Gasket, Shifter Assembly Cover Bushing, Shift Rail Lever, Rear Offset Shift Pin, Rear Offset Shift Lever Roll Cup, Isolator Shifter Assembly Bolt, Shifter Assembly Distance Piece, Shift Cover Bolt Sleeve, Insulating Cover, Shifter Assembly Screw, Shifter Assembly Cover Boot, Shifter Seal and Boot, Rear Output Bolt, Transmission Extension Housing Plug, Drain Shim, Countershaft Cup, Countershaft Bearing Bearing, Countershaft Tapered Countershaft Bearing, Countershaft Tapered Cup, Countershaft Bearing Washer, Thrust Gear, 6th Drive Bearing, 6th Gear Needle Fork, Reverse Shift Pad, Reverse Shift Fork Circlip Blocker Ring, 6th Gear Spacer Ring, Snap Synchroniser Assembly, 5th/6th Spring, 5th/6th Synchroniser Key, 5th/6th Synchroniser Hub, 5th/6th Synchroniser Ring, 5th/6th Synchroniser Fork, 5th/6th Shift Pad, 5th/6th Shift Fork Circlip Blocker Ring, 5th Gear Gear, 5th Drive Bearing, 5th Gear Needle Extension, Countershaft Bearing, Countershaft Extension Tapered Cup, Countershaft Extension Bearing Shim, Countershaft Extension Funnel, Oil Bolt, Reverse Idler Shaft Bracket Bracket, Reverse Idler Shaft Washer, Reverse Idler Gear Thrust Gear, Reverse Idler Bearing, Reverse Idler Gear Roller Shaft, Reverse Idler Gear Washer, Reverse Idler Gear Thrust Rail Assembly, 5th/6th, Reverse Shift Pin, Roll Collar Rail, Shift Lever, 5th/6th Shift Rail Pad, 5th/6th Shift Rail Lever Bushing, 5th/6th Shift Rail Lever Pin, Roll Lever, Reverse Shift Rail Rail Assembly, 1st/2nd, 3rd/4th Shift Fork, 1st/2nd Shift Pad, 1st/2nd Shift Fork Link, Shift Rail, 1st/2nd 3rd/4th Shift Pin, Roll Pin, Selector Plate, Interlock Link, Shift Fork, 3rd/4th Shift Pad, 3rd/4th Shift Fork Solenoid, Reverse Lockout O-Ring, Reverse Lockout Solenoid Body Assembly, Reverse Lockout Bolt, Reverse Lockout Assembly O-Ring, Reverse Lockout Assy Circlip Plunger, Reverse Lockout Spring, Reverse Lockout Outer Collar, Reverse Lockout C Clip Spring, Reverse Lockout Inner Body, Reverse Lockout Housing, Clutch Bolt, Clutch Housing to Adaptor Assembly, Clutch Slave Cylinder Bolt, Clutch Slave Cylinder Bolt, Transmission Adaptor Plate Spacer Tube, Vent Fitting, Vent Tube O-Ring, Mainshaft Legend - Transmission Components

7 POWER FLOWS The input shaft drive gear, third, second and first speed gears are in constant mesh with the countershaft gear. As the countershaft gear extension is splined to the end of the countershaft gear, reverse drive gear at the end of this extension, rotates with the countershaft gear. Therefore, when the engine is running with the clutch engaged, engine torque is transferred to the input shaft drive gear and through the countershaft gear to the third, second, first speed and reverse gears at all times. The schematics in Figure 7B3-5 relate to the following descriptions: Neutral In neutral, with the clutch engaged, the input shaft drive gear turns the countershaft gear and countershaft extension. The countershaft gear turns the constant mesh gears of 3rd, 2nd, 1st and reverse gears because no synchroniser assemblies are engaged. As these constant mesh gears are supported on roller bearings, they will also rotate with the countershaft gear. As the 5th/6th compound gear is splined to the mainshaft, these constant mesh gears, mounted on the countershaft extension, will remain stationery while the vehicle is stopped. First Gear In first gear, the first/second speed synchroniser ring is moved rearward to engage the first speed gear, which is being turned by the countershaft gear. Because the first/second speed synchroniser hub is splined to the mainshaft, torque is transferred to the mainshaft from the first speed gear through the synchroniser ring and hub, at a speed reduction of 2.66:1. Second Gear In second gear, the first/second speed synchroniser ring is moved forward to engage the second speed gear, which is being turned by the countershaft gear. Because the first/second speed synchroniser hub is splined to the mainshaft, torque is transferred to the mainshaft from the second speed gear through the synchroniser ring and hub, at a speed reduction of 1.78:1. Third Gear In selecting third gear, the first/second speed synchroniser ring moves to the neutral position and the third/fourth speed synchroniser ring is moved rearward to engage the third speed gear. As this gear is being turned by the countershaft gear, the engagement of the ring with the third speed gear, torque is transferred to the mainshaft because the third/fourth speed synchroniser hub is splined to the mainshaft. The mainshaft the turns at a speed reduction of 1.30:1 Fourth Gear In fourth gear, the third/fourth speed synchroniser ring is moved forward to engage the input shaft drive gear. This engagement of the input shaft drive gear with the third/fourth synchroniser ring and hub assembly, transfers torque directly to the mainshaft. While the countershaft gear and countershaft extension is still rotating, no torque transfer takes place but the spinning gear continues to lubricate the internal transmission components by the splash method. As the mainshaft is effectively joined to the input shaft, the drive is direct with a ratio of 1.00:1. Fifth Gear In fifth gear, which is the first of the overdrive ratios, the first/second and third/fourth speed synchroniser rings must be in the neutral position. The fifth/sixth speed synchroniser ring is moved rearward to engage the fifth speed drive gear, supported on the countershaft extension by a caged needle roller bearing. This engagement of the ring with the fifth speed constant mesh gear, allows torque to be transferred from the countershaft gear extension to the mainshaft, via the splined synchromesh hub and the splined fifth/sixth speed compound driven gear. This speed generates an overdrive ratio of 0.74:1. Sixth Gear In sixth gear, the fifth/sixth speed synchroniser ring is moved forward to engage the sixth speed drive gear, supported on the countershaft extension by a caged needle roller bearing. This engagement of the ring with the sixth speed constant mesh gear, allows torque to be transferred from the countershaft gear extension to the mainshaft, via the splined synchromesh hub and the splined fifth/sixth speed compound driven gear. This speed generates an overdrive ratio of 0.50:1. Reverse Gear In reverse gear, the reverse synchroniser ring is moved rearward to engage the mainshaft mounted, reverse driven gear. This allows torque to be transferred from the countershaft extension gear through the reverse idler gear (reversing direction of rotation) to the mainshaft reverse driven gear. As the reverse synchromesh hub is splined to the mainshaft, this causes the mainshaft to rotate in the opposite direction to the input shaft drive gear, at a speed reduction of 2.90:1.

8 MANUAL TRANSMISSION POWER FLOWS Figure 7B3-5

9 The transmission serial number is located on a self-adhesive decal attached to the top of the transmission case. This number provides coded information which could be significant to parts interpretation and should be referred to when ordering replacement parts. In addition, an identification tag is attached to the transmission under an extension housing bolt, on the right hand side. Refer Figure 7B TRANSMISSION SERIAL NUMBER Figure 7B3-6

10 2. SERVICING INFORMATION 2.1 RECOMMENDED LUBRICANT The recommended lubricant for the T56 manual transmission is Dexron III automatic transmission fluid to Holden s Specification HN The transmission lubricant capacity is approximately 4.4 litres.

11 2.2 CHECKING TRANSMISSION LUBRICANT LEVEL Important: This transmission is classified as being a Fill for Life transmission and checking the lubricant level is not recommended. The only time that fluid level checking would be appropriate, would be after correction of a fluid leak that did not require the transmission to be fully drained and/or removed from the vehicle. 1. Raise the vehicle front and rear and support on safety stands, ensuring that the vehicle is level. Refer to Section 0A GENERAL INFORMATION of the VT Series I Service Information, for the location of jacking points. 2. Place a drain tray beneath transmission and remove transmission filler plug (1) from left hand side of transmission case (2), using a 3/8 drive socket bar. NOTE: Depending on the severity of the loss, fluid will probably flow from the filler plug hole, following removal. 3. Allow excess fluid to drain until flow stops. If required, top up fluid level until it does flow out. 4. Clean the threads of the filler plug, apply thread sealant such as Loctite 565 or equivalent (GM P/N ), then reinstall filler plug, tightening to the correct torque specification. Do not apply Teflon thread tape to the plug threads. TRANSMISSION FILLER PLUG TORQUE SPECIFICATION Nm 5. Remove the back-up lamp switch as detailed in 3.1 BACK-UP LAMP SWITCH, Replace in this Section. 6. Using commercially available fluid dispensing equipment, add a measured, 0.5 litres of the recommended lubricant to the transmission, via the back-up lamp switch threaded hole in the transmission case. 7. Reinstall the back-up lamp switch, as detailed in 3.1 BACK-UP LAMP SWITCH, Replace in this Section, then lower the vehicle to the ground. Figure 7B3-1

12 Should a lubricant change be required, then the following procedure should be adopted. 1. To drain transmission, jack up vehicle front and rear and support on safety stands. Refer to Section 0A GENERAL INFORMATION of the VT Series II Service Information, for the location of jacking points. 2. Place a drain tray beneath transmission and remove filler plug (refer 1 in Figure 7B3-7) and then the drain plug from the transmission extension housing ( 1 in Figure 7B3-8), using a 3/8 drive socket bar. 3. After draining, clean the threads of the drain plug, apply thread sealant such as Loctite 565 or equivalent (GM P/N ) then reinstall, tightening to the correct torque specification. NOTE: Do not apply Teflon thread tape to the plug threads. TRANSMISSION DRAIN PLUG TORQUE SPECIFICATION Nm 4. Refill transmission to correct level, refer to 2.2 CHECKING TRANSMISSION LUBRICANT LEVEL in this Section. 2.3 DRAINING AND REFILLING TRANSMISSION Figure 7B3-8

13 REPLACE 1. Raise front of vehicle and support on safety stands. Refer to Section 0A GENERAL INFORMATION of the VT Series II Service Information, for the location of jacking points. 2. Remove wiring harness connector (1) from switch, located on the right hand side of the transmission case. 3. MINOR SERVICE OPERATIONS 3.1 BACK-UP LAMP SWITCH 3. Loosen, then remove switch (arrow) from the transmission case. 4. Apply Loctite 565 or equivalent (GM P/N ), to the cleaned threads of the back-up lamp switch. 5. Install switch to transmission case and tighten to the correct torque specification. Figure 7B3-9 BACK-UP LAMP SWITCH TORQUE SPECIFICATION Nm 6. Install wiring harness connector to switch. 7. Remove safety stands and lower vehicle to ground. 8. Check back-up lamp operation. Figure 7B3-10

14 REPLACE 1. Jack up vehicle front and rear and support on safety stands. Refer to Section 0A GENERAL INFORMATION of the VT Series II Service Information, for the location of jacking points. 2. Remove the two bolts (2) securing the catalytic converter bracket (1) to the catalytic converters. 3.2 SPEED SENSOR 3. Scribe around each of the transmission support crossmember mounting points to the vehicle underbody, to provide an alignment reference for reassembly. NOTE: This step is critical to the correct powertrain alignment on reassembly. If not carried out, then vehicle vibration and/or handling problems may result. 4. Support the transmission with a suitable lifting device, then remove the four engine mounting crossmember bolts, followed by the two rear mount to crossmember nuts. Set the crossmember to one side. 5. Lower the rear of the transmission enough to gain clear access to the sensor. Figure 7B Remove the speed sensor wiring harness connector (1) from the sensor (3). 7. Remove speed sensor mounting bracket screw (2) from the transmission extension housing, then remove the sensor (3). 8. Installation is the reverse of removal except for the following points; a. Tighten the speed sensor to mounting bracket retaining screw (2) to the correct torque specification. SPEED SENSOR BRACKET SCREW TORQUE SPECIFICATION Nm b Connect the speed sensor lead connector (1) to the sensor. Figure 7B3-12 Figure 7B3-13

15 9. Raise the transmission, then install the four crossmember to side frame bolts (3), aligning the crossmember (2) with the scribed lines made prior to disassembly. Tighten the bolts (3) to the correct torque specification. REAR CROSSMEMBER TO SIDE FRAME MEMBER BOLT TORQUE SPECIFICATION Nm 10. Remove the lifting device from the transmission, centralise the rear mount studs in the crossmember holes, then reinstall the nuts (4), tightening to the correct torque specification. REAR CROSSMEMBER TO REAR MOUNTING ATTACHING NUT TORQUE SPECIFICATION Nm 11. Reinstall the two catalytic converter bracket (6) bolts, tightening to the correct torque specification. CATALYTIC CONVERTER BRACKET BOLT TORQUE SPECIFICATION Nm 12. Lower the vehicle and road test to check speedometer operation. Figure 7B3-14

16 REPLACE 1. Jack up vehicle front and rear and support on safety stands. Refer to Section 0A GENERAL INFORMATION of the VT Series II Service Information, for the location of jacking points. 2. Remove the two bolts (2) securing the catalytic converter bracket (1) to the catalytic converters. 3.3 TRANSMISSION SUPPORT MOUNT 3. Scribe around each of the transmission support crossmember mounting points to the vehicle underbody, to provide an alignment reference for reassembly. NOTE: This step is critical to the correct powertrain alignment on reassembly. If not carried out, then vehicle vibration and/or handling problems may result. 4. Support the transmission with a suitable lifting device, then remove the four engine mounting crossmember bolts. 5. Lower the transmission slightly, then remove the two rear mount to crossmember nuts. Set the crossmember to one side. Figure 7B3-15 Figure 7B3-16

17 6. Remove the two bolts (5) securing the mount (1) to the transmission extension housing, then remove the mount from the vehicle. 7. Reinstall the mount (1) to the transmission extension housing, install the two bolts (5) and tighten to the correct torque specification. TRANSMISSION SUPPORT MOUNT BOLT TORQUE SPECIFICATION Nm 8. Raise the transmission slightly, then reinstall the four crossmember to side frame bolts (3), aligning the crossmember (2) with the scribed lines made prior to disassembly. Tighten the bolts (3) to the correct torque specification. REAR CROSSMEMBER TO SIDE FRAME MEMBER BOLT TORQUE SPECIFICATION Nm 9. Remove the lifting device from the transmission, centralise the rear mount studs in the crossmember holes, then reinstall the nuts (4), tightening to the correct torque specification. REAR CROSSMEMBER TO REAR MOUNTING ATTACHING NUT TORQUE SPECIFICATION Nm 10. Reinstall the two catalytic converter bracket (6) bolts, tightening to the correct torque specification. CATALYTIC CONVERTER BRACKET BOLT TORQUE SPECIFICATION Nm 11. Lower the vehicle and road test to check speedometer operation. Figure 7B3-17

18 REMOVE 1. Jack up vehicle front and rear and support on safety stands. Refer to Section 0A GENERAL INFORMATION of the VT Series II Service Information, for the location of jacking points. 2. Remove the two bolts (2) securing the catalytic converter bracket (1) to the catalytic converters. 3.4 REVERSE LOCKOUT SOLENOID ASSEMBLY 3. Scribe around each of the transmission support crossmember mounting points to the vehicle underbody, to provide an alignment reference for reassembly. NOTE: This step is critical to the correct powertrain alignment on reassembly. If not carried out, then vehicle vibration and/or handling problems may result. 4. Support the transmission with a suitable lifting device, then remove the four engine mounting crossmember bolts. 5. Lower the transmission slightly, then remove the two rear mount to crossmember nuts. Set the crossmember to one side. Figure 7B Lower the transmission sufficiently to gain access to the reverse lockout solenoid assembly (5). 7. Remove wiring harness connector (4) from the reverse lockout solenoid (5), after depressing the locking tab. 8. Remove the reverse lockout solenoid assembly mounting screw (6), then remove the assembly from the transmission extension housing by rotating back and forth while pulling on the assembly. Figure 7B3-19 Figure 7B3-20

19 DISASSEMBLE 1. While holding the lockout body (2) in a vice fitted with soft jaws, unscrew the reverse lockout solenoid (1) from the body (2), then remove the O-ring seal (3). If the O-ring seal (3) is undamaged, it can be re-used. 2. Remove the O-ring (4) from the body (2). If the O-ring seal is undamaged it can also be reused. 3. Remove circlip (5), using suitable pliers, from the body (2). 4. Remove lockout plunger assembly (6) from the body (2), then remove the inner spring (7). 5. Compress the reverse lockout plunger (6) and collar (8) in a bench vice, then remove the C clip (9). CAUTION: The reverse lockout assembly is under a strong spring force. Exercise care when removing C clip (9), as injury could result. 6. Release the vice and disassemble the collar (8) and spring (10) from the plunger (6). 7. Clean all parts in a suitable solvent and blow dry with compressed air. CAUTION: Wear safety glasses to avoid eye injury. 8. Inspect all parts for damage or wear and springs for broken or damaged coils. 9. For solenoid testing procedure, refer to Section 6C3 POWERTRAIN MANAGEMENT - GEN III V8 ENGINE, of the VT Series II Service Information. Figure 7B3-21 REASSEMBLE NOTE: Refer Figure 7B3-21 for component identification. 1. Compress the reverse lockout plunger (6), spring (10) and collar (8) in a bench vice, then install the C clip (9). CAUTION: Wear safety glasses to avoid eye injury. 2. Install the inner spring (7) into the end of the lockout plunger assembly (6), then install the assembly into the reverse lockout body (2). 3. Install circlip (5), using suitable pliers, to retain the lockout plunger assembly (5). 4. Install the reverse lockout solenoid (1) and O- ring, tightening to the correct torque specification. REVERSE LOCKOUT SOLENOID TORQUE SPECIFICATION Nm 5. Install the O-ring (4) to the body (2).

20 REINSTALL The installation process is the reverse of removal operations except for the following: 1. After reinstalling the reverse lockout assembly (5), install the retaining bolt (6) and tighten to the correct torque specification. REVERSE LOCKOUT ASSEMBLY BOLT TORQUE SPECIFICATION Nm 2. Reinstall the wiring harness connector (4) to the reverse lockout solenoid. 3. Raise the transmission slightly, then reinstall the four crossmember to side frame bolts (3), aligning the crossmember (2) with the scribed lines made prior to disassembly. Tighten the bolts (3) to the correct torque specification. REAR CROSSMEMBER TO SIDE FRAME MEMBER BOLT TORQUE SPECIFICATION Nm 4. Remove the lifting device from the transmission, centralise the rear mount studs in the crossmember holes, then reinstall the nuts (4), tightening to the correct torque specification. REAR CROSSMEMBER TO REAR MOUNTING ATTACHING NUT TORQUE SPECIFICATION Nm 5. Reinstall the two catalytic converter bracket (6) bolts, tightening to the correct torque specification. CATALYTIC CONVERTER BRACKET BOLT TORQUE SPECIFICATION Nm 6. Lower the vehicle and road test to check speedometer operation. Figure 7B3-22 Figure 7B3-23

21 3.5 CONTROL LEVER KNOB AND BOOT ASSEMBLY NOTE: The gearshift lever knob and console boot are manufactured as a single component. Do not attempt to remove the gearshift lever knob separately to the boot. REMOVE 1. With the fingers of one hand hooked under the edge of the gearshift lever boot as shown, carefully release each of the 8 plastic retainers and free the gearshift lever boot from the console cap. 2. Lift the gearshift lever boot enough to enable a firm grasp to be made on the gearshift lever with the left hand, then grasp the gearshift knob with the right. 3. While rocking the knob sideways, and with an upward force applied, dislodge the knob retaining claws from the lever. 4. Remove the gearshift lever knob and boot assembly, from the gearshift lever. Figure 7B3-24 Figure 7B3-25 REINSTALL 1. Reinstall the knob and boot assembly over the gearshift lever, align the knob in the correct attitude and then bump the knob onto the gearshift lever until the retaining claws engage with the groove in the lever. 2. Align the boot retaining clips with the hole in the console cap, then carefully seat the boot retainers into the console cap until each clip engages correctly.

22 3.6 GEARSHIFT CONTROL LEVER AND REMOTE SHIFTER SHAFT BOOT REMOVE 1. Disconnect the battery earth lead. 2. Remove the gearshift lever knob and boot assembly, from the gearshift lever. Refer to 3.5 CONTROL LEVER KNOB AND BOOT ASSEMBLY in this Section, for the necessary procedure. 3. Remove the centre console assembly, including the console cap. Refer to Section 1A3, INSTRUMENT PANEL AND CONSOLE, of the VT Series I Service Information for the necessary procedure. 4. Slip the insulator sock (7) from the control lever (1) and set it to one side. 5. Using a 10 mm socket, remove the two bolts (2) securing the control lever (1) to the gearshift remote shift lever shaft (3), then lift the control lever free. 6. If required, remove the four bolts (5) securing the gearshift remote shift lever boot retaining plate (6) to the floor pan, then remove the boot (4) and retaining plate (6). CLEAN AND INSPECT 1. Inspect the gearshift remote shift lever boot (4) for tears or other damage, replacing as required. 2. Clean the threads of the control lever bolts (2) and check for thread damage. Figure 7B3-26

23 REINSTALL 1. If removed, install the gearshift remote lever boot (4) and plate (6) and secure with the four bolts (5), tightening to the correct torque specification. GEARSHIFT REMOTE LEVER BOOT PLATE BOLT TORQUE SPECIFICATION Nm 2. Apply thread sealant such as Loctite 242 or equivalent (to Holden s Specification HN 1256 Class 2, Type 2), to the cleaned threads of the control lever retaining bolts (2). 3. Install the control lever (1) over the remote shift lever shaft (3), install the two bolts (2), tightening to the correct torque specification. GEARSHIFT LEVER TO REMOTE SHIFT LEVER SHAFT BOLT TORQUE SPECIFICATION Nm 4. Reinstall the insulator sock (7) over the remote shift lever (1). 5. Reinstall centre console assembly, including the console cap. Refer to Section 1A3, INSTRUMENT PANEL AND CONSOLE, of the VT Series I Service Information for the necessary procedure. 6. Reinstall the gearshift knob and boot assembly over the gearshift lever, align the knob in the correct attitude and then bump the knob onto the gearshift lever until the retaining claws engage with the groove in the lever. 7. Align the gearshift boot retaining clips with the hole in the console cap, then carefully seat the boot retainers into the console cap until each clip engages correctly. 8. Reconnect battery earth lead. 9. Road test vehicle and check for correct gearshift operations.

24 4. MAJOR SERVICE OPERATIONS 4.1 TRANSMISSION OUTPUT SHAFT SEAL AND BOOT REMOVE 1. Disconnect battery earth lead. 2. Raise front and rear of vehicle, supporting on safety stands. Refer to Section 0A GENERAL INFORMATION of the VT Series I Service Information, for the location of jacking points. 3. Scribe around each of the transmission support crossmember mounting points to the vehicle underbody, to provide an alignment reference for reassembly. NOTE: This step is critical to the correct powertrain alignment on reassembly. If not carried out, then vehicle vibration and/or handling problems may result. 4. Remove the two bolts (2) securing the catalytic converter bracket (1) to the catalytic converters. Figure 7B3-27 Figure 7B3-28

25 5. Support the transmission with a suitable lifting device, then remove the four engine rear crossmember to side frame attaching bolts (3). 6. Lower the transmission slightly, then remove the two transmission mount to crossmember nuts (4). Set the crossmember (2) to one side. 7. Remove the two bolts (5) securing the transmission mount (1) to the transmission extension, then remove the mount (1) and bracket (6) from the vehicle. NOTE: Illustration does not show transmission jack in position, for clarity of the crossmember orientation. 8. Remove the nuts from the two bolts (7) securing the catalytic converter bracket (6) to the transmission extension, remove the bolts and bracket and set to one side. 9. Lower the transmission enough to provide clearance for the propeller shaft rubber coupling when the propeller shaft is removed. Figure 7B Remove centre bearing carrier to underbody reinforcement bolts and spacers. NOTE: For correct reassembly, take particular note of any spacer arrangement that may be fitted, observing any side to side variations and the orientation of the bracket offset. 11. Support centre bearing assembly to prevent any angular deflection of the constant velocity joint that exceeds 8. Should this angle be exceeded, then damage to the boot and/or constant velocity joint may occur. 12. Place a drain tray beneath transmission. 13. Remove nuts (2) and bolts (1) holding propeller shaft rear universal joint flange to pinion flange, then disengage rear universal joint flange from pinion flange. NOTE: The two flanges have paint alignment marks (A) that are assembled as close together as possible. If the marks are not visible, scribe a mark on both flanges so that they will be reinstalled in their original position. 14. Disconnect the propeller shaft from the rear flange and, moving the propeller shaft slightly to the left hand side of the vehicle, pull the assembly to the rear of vehicle, enough to disengage the slip joint from the transmission mainshaft. Figure 7B3-30 Figure 7B3-31

26 15. Using a seal remover such as Tool No (also released as E308), remove the seal (1) from the transmission extension housing. NOTE: Should Tool No not be available, then it will be necessary to remove the seal by prising it from the extension housing with a suitable lever such as a screwdriver. If this method is used, take care not to scratch the bore of the extension housing during the removal process. Figure 7B3-32 REINSTALL 1. After lubricating the seal lip with transmission lubricant, use seal installer J and install the new seal into the rear of the extension housing. 2. Install the propeller slip joint into the rear of the transmission, then lift the propeller shaft upward (while maintaining and angular deflection less than 8 ) and install centre bearing carrier to underbody reinforcement. Ensure all spacers are replaced in the same positions, noted on removal, then install retaining bolts. 3. Assemble propeller shaft rear universal joint flange to pinion flange and install attaching bolts and nuts. 4. Tighten all propeller shaft attaching bolts to the correct torque specification. CENTRE BEARING CARRIER TO UNDERBODY REINFORCEMENT BOLT TORQUE SPECIFICATION Nm PROPELLER SHAFT REAR UNIVERSAL JOINT FLANGE TO PINION FLANGE BOLT Nm TORQUE SPECIFICATION 5. Reinstall the catalytic converter bracket (6) to the transmission extension, install the bolts (7) and nuts, then tighten to the correct torque specification. Figure 7B3-33

27 CONVERTER BRACKET TO TRANSMISSION EXTENSION BOLT TORQUE SPECIFICATION Nm 6. Reinstall the transmission mount (1) to the transmission extension, install the two bolts (5) and tighten to the correct torque specification. TRANSMISSION MOUNT TO EXTENSION HOUSING BOLT Nm TORQUE SPECIFICATION 7. Raise the transmission slightly, then reinstall the four crossmember to side frame bolts (3), aligning the crossmember (2) with the scribed lines made prior to disassembly. Tighten the bolts (3) to the correct torque specification. REAR CROSSMEMBER TO SIDE FRAME MEMBER BOLT Nm TORQUE SPECIFICATION 8. Remove the lifting device from the transmission, centralise the rear mount studs in the crossmember holes, then reinstall the nuts (4), tightening to the correct torque specification. REAR CROSSMEMBER TO TRANSMISSION MOUNT NUT Nm TORQUE SPECIFICATION 9. Reinstall the two catalytic converter bracket (6) bolts, tightening to the correct torque specification. CATALYTIC CONVERTER BRACKET BOLT TORQUE SPECIFICATION Nm 10. Check the transmission fluid level. Refer to 2.2 CHECKING TRANSMISSION LUBRICANT LEVEL in this Section. Top up as required. 11. Lower the vehicle reconnect battery ground lead. 12. Lower the vehicle and road test to check vehicle operation. Figure 7B3-34

28 REMOVE 1. Disconnect battery ground lead. 2. With the fingers of one hand hooked under the edge of the gearshift lever boot as shown, carefully release each of the 8 plastic retainers and free the gearshift lever boot from the console cap. NOTE: The gearshift lever knob and console boot are manufactured as a single component. Do not attempt to remove the gearshift lever knob separately to the boot. 4.2 TRANSMISSION ASSEMBLY 3. Lift the gearshift lever boot enough to enable a firm grasp to be made on the gearshift lever with the left hand, then grasp the gearshift knob with the right. 4. While rocking the knob sideways, and with an upward force applied, dislodge the knob retaining claws from the lever. 5. Remove the gearshift lever knob and boot assembly, from the gearshift lever. Figure 7B Remove the centre console. Refer Section 1A3 INSTRUMENT PANEL AND CONSOLE, of the VT Series I Service Information for the necessary procedure. 7. Slip the insulator sock (7) from the control lever (1). 8. Using a 10 mm socket, remove the two bolts (2) securing the control lever (1) to the remote shifter shaft (3), then lift the control lever free. 9. Remove the four bolts (5) securing the remote shift lever boot retaining plate (6) to the floor pan, then remove the boot (4) and retaining plate (6). 10. Select third gear to allow the remote shifter shaft (3) to clear the opening in the floor pan, when the transmission is lowered for removal. Figure 7B3-36 Figure 7B3-37

29 11. Raise vehicle, preferably on a drive-on hoist or a four post hoist. This preference is based on the fact that the transmission is very heavy and the use of a transmission jack will be required for effective transmission removal and installation. 12. Disconnect wiring harness connectors from each of the two oxygen sensors. 13. Depending on the reason for removal, it might be appropriate to drain the transmission lubricant into a clean container. Place a drain tray beneath transmission and remove the drain plug (1) using a 3/8 drive socket bar. When transmission has fully drained, clean the threads of the drain plug, apply thread sealant such as Loctite 565 or equivalent (GM P/N ), then reinstall, tightening to the correct torque specification, using a 3/8 drive adaptor and a torque wrench. NOTE: Do not apply Teflon thread tape to the plug threads. TRANSMISSION DRAIN PLUG TORQUE SPECIFICATION Nm Figure 7B Scribe around each of the transmission support crossmember mounting points to the vehicle underbody, to provide an alignment reference for reassembly. NOTE: This step is critical to the correct powertrain alignment on reassembly. If not carried out, then vehicle vibration and/or handling problems may result. 15. Remove the two bolts (2) securing the catalytic converter bracket (1) to the catalytic converters. Figure 7B3-39 Figure 7B3-40

30 16. Support the transmission with a suitable lifting device, then remove the four engine rear crossmember to side frame attaching bolts (3). 17. Lower the transmission slightly, then remove the two rear mount to crossmember nuts (4). Set the crossmember (2) to one side. 18. Remove the two bolts (5) securing the rear mount (1) to the transmission extension, then set the mount to one side. 19. Remove the two nuts and bolts (7) securing the catalytic converter bracket (6) to the transmission extension, then remove the bracket (6) from the vehicle. NOTE: Illustration does not show transmission jack in position, for clarity of the crossmember orientation. 20. Remove centre bearing carrier (2) to underbody reinforcement bolts (1) and spacers, if fitted. NOTE: For correct reassembly, take particular note of any spacer arrangement that may be fitted, observing any side to side variations and the orientation of the bracket (2) offset. 21. Support centre bearing assembly (3) to prevent any angular deflection of the constant velocity joint that exceeds 8. Should this angle be exceeded, then damage to the boot and/or constant velocity joint may occur. 22. Place a drain tray beneath transmission or insert a plug into the rear of the extension housing. 23. Remove nuts (2) and bolts (1) holding the propeller shaft rear universal joint flange to pinion flange, then disengage rear universal joint flange from pinion flange. NOTE: The two flanges have paint alignment marks (A) that are assembled as close together as possible. If the marks are not visible, scribe a mark on both flanges so that they will be reinstalled in their correct position. 24. Disconnect the propeller shaft from the rear flange and, moving the propeller shaft slightly to the left hand side of the vehicle, pull the assembly toward the rear of vehicle, sufficient to disengage the slip joint from the transmission mainshaft. Figure 7B3-41 Figure 7B3-42 Figure 7B3-43

31 25. Remove the speed sensor wiring harness connector (1) and the connector (4) from the reverse lockout solenoid. (5). 26. Remove the wiring harness connector from the back-up lamp switch, located on the right hand side of the transmission. 27. Cut the tie strap securing the powertrain harness to the breather pipe (not shown), remove the harness from the clip under the right hand top extension housing bolt and secure to one side. Figure 7B Remove the starter motor. Refer to Section 6D3-2, STARTING SYSTEM - GEN III V8 ENGINE, of the VT Series II Service Information, for the necessary procedure. 29. Remove the right close-out cover and bolt. Figure 7B3-45 Figure 7B3-46

32 30. Remove the left close-out cover and bolt. 31. Place a suitable container under the clutch hydraulic hose area, then disconnect the hydraulic pipe (1) from the hydraulic hose (2), at the bracket attached to the vehicle subframe. NOTE: Use a back-up spanner on the hydraulic hose (2) when loosening the pipe fitting. 32. Remove the hose retaining clip (3) using combination pliers, then remove the hose from the bracket. NOTE: Plug the hydraulic hose (2) and master cylinder pipe (1) open ends to stop fluid loss and dirt entry. Figure 7B Lower the transmission enough to gain access to the bolts (2) fastening the clutch housing (1) to the rear of the engine. 34. Progressively loosen then remove six of the eight clutch housing to engine bolts (2). Figure 7B3-48 Figure 7B3-49

33 35. After removing the two remaining bolts (1) that also secure the starter motor heat shield (2), unclip the heat shield from the starter motor and set to one side. 36. Pull the transmission rearward, just enough to clear the locating dowels, then rotate the transmission through 90 to the right to gain clearance at the floor pan. 37. With the transmission supported by the transmission jack, continue to withdraw the transmission, taking care not to place any loading on the clutch driven plate centre splines that could cause driven plate distortion. NOTE: It is most important to prevent permanent distortion of the driven plate, because replacement would then be required. 38. When the transmission input shaft is clear of the clutch pressure plate, the transmission can be lowered and removed from the vehicle. NOTE: Take particular care when lowering the transmission, that damage to the oxygen sensors does not occur. Figure 7B3-50

34 REINSTALL 1. Select 3rd gear. 2. If removed, install the clutch slave cylinder pipe (1) to the slave cylinder (2), and tighten to the correct torque specification. CLUTCH FLUID PIPE FITTING TO SLAVE CYLINDER TORQUE SPECIFICATION Nm 3. Sparingly apply 10% molybdenum disulphide grease, such as Molybond GA 10 (or equivalent to Holden s Specification HN 1271) to the bearing face of the clutch throwout bearing, mounted to the slave cylinder (2), the splines and spigot of the input shaft. 4. With the transmission on its side, with the top surface facing the right hand side of the vehicle, use a transmission jack to raise the transmission and install input shaft into the splines of clutch driven plate. 5. Push transmission in toward engine block. It may be necessary to rotate the mainshaft after temporarily installing the propeller shaft, to assist in spline alignment. Figure 7B When installed up to the locating dowel pins, rotate the transmission counter-clockwise 90, then push fully home. 7. Clip the heat shield (2) onto the starter motor, then install two clutch housing to engine block bolts (1), to retain. 8. Install the remaining six clutch housing to engine block bolts and tighten all bolts in the sequence shown, to the specified torque. CLUTCH HOUSING TO ENGINE BLOCK BOLT TORQUE SPECIFICATION Nm Figure 7B3-52 Figure 7B3-53

35 9. Reinstall wiring harness connectors to the back up lamp switch, reverse lockout solenoid, speed sensor and each of the oxygen sensors. 10. Secure the powertrain wiring harness to the transmission vent pipe, using a cable tie. 11. Reinstall propeller shaft slip joint into the transmission mainshaft, supporting the centre, constant velocity joint at an angle not exceeding 8, to avoid damage to the joint and/or boot. 12. Lift propeller shaft upward and install centre bearing carrier to underbody reinforcement, ensuring that all spacers are replaced in the same positions, noted on removal. Install retaining bolts. 13. Assemble propeller shaft rear universal joint flange to pinion flange, aligning marks noted on removal. Install attaching bolts and nuts. 14. Tighten all propeller shaft attaching bolts to the correct torque specification. CENTRE BEARING CARRIER TO UNDERBODY REINFORCEMENT TORQUE SPECIFICATION PROPELLER SHAFT REAR UNIVERSAL JOINT FLANGE BOLT TORQUE SPECIFICATION Nm Nm

36 15. Reinstall the catalytic converter bracket (6) to the transmission extension, reinstall the bolts (7) and nuts, then tighten to the correct torque specification. CONVERTER BRACKET TO TRANSMISSION EXTENSION BOLT TORQUE SPECIFICATION Nm 16. Reinstall the rear mount (1) to the transmission extension, install the two bolts (5) and tighten to the correct torque specification. TRANSMISSION MOUNT TO EXTENSION HOUSING BOLT TORQUE SPECIFICATION Nm 17. Raise the transmission slightly, then reinstall the four crossmember to side frame bolts (3), aligning the crossmember (2) with the scribed lines made prior to disassembly. Tighten the bolts (3) to the correct torque specification. REAR CROSSMEMBER TO SIDE FRAME MEMBER BOLT TORQUE SPECIFICATION Nm Important: This step is critical to the correct powertrain alignment. If not carried out, then vehicle vibration and/or handling problems may result. 18. Remove the lifting device from the transmission, centralise the rear mount studs in the crossmember holes, then reinstall the nuts (4), tightening to the correct torque specification. REAR CROSSMEMBER TO TRANSMISSION MOUNT NUT TORQUE SPECIFICATION Nm 19. Reinstall the two catalytic converter bracket (6) bolts, tightening to the correct torque specification. CATALYTIC CONVERTER BRACKET BOLT TORQUE SPECIFICATION Nm 20. Install clutch hydraulic hose to the bracket on the sub-frame rail, then install the pipe fitting, tightening to the correct torque specification. Use a back-up spanner on the hydraulic hose end fitting. CLUTCH HYDRAULIC PIPE TO TORQUE SPECIFICATION Nm 21. If transmission fluid was drained during the removal operation, then refill, as described in 2.3 DRAINING AND REFILLING TRANSMISSION, in this Section. 22. Reinstall the right and left close-out covers, secure with a bolt in each and tighten to the correct torque specification. LEFT AND RIGHT CLOSE-OUT COVER RETAINING BOLT Nm TORQUE SPECIFICATION 23. Reinstall the starter motor. Refer to Section 6D3-2, STARTING SYSTEM - GEN III V8 ENGINE of the VT Series II Service Information, for the necessary procedure. 24. Lower vehicle to the ground. Figure 7B3-54

37 25. Reinstall the remote shift lever boot and retainer. Install the four bolts and tighten to the correct torque specification. REMOTE SHIFT LEVER BOOT PLATE BOLT TORQUE SPECIFICATION Nm 26. Reinstall the gearshift control lever. Secure with bolts that have Loctite 242 or equivalent (to Holden s Specification HN 1256 Class 2, Type 2), applied to cleaned threads. Tighten to the correct torque specification, then reinstall the insulator over the control lever. GEARSHIFT CONTROL LEVER BOLT TORQUE SPECIFICATION Nm 27. Reinstall centre console assembly, including the console cap. Refer to Section 1A3, INSTRUMENT PANEL AND CONSOLE, of the VT Series I Service Information for the necessary procedure. 28. Reinstall the gearshift knob and boot assembly over the gearshift lever, align the knob in the correct attitude and then bump the knob onto the gearshift lever until the retaining claws engage with the groove in the lever. 29. Align the gearshift boot retaining clips with the hole in the console cap, then carefully seat the boot retainers into the console cap until each clip engages correctly. 30. Reconnect battery earth lead. 31. Road test vehicle and check transmission, clutch and gearshift operations.

38 1. Remove transmission assembly from vehicle. Refer 4.2 TRANSMISSION ASSEMBLY - REMOVE, in this Section. CLUTCH HOUSING AND SLAVE CYLINDER 2. Remove the two bolts (1) securing the clutch slave cylinder pipe to the transmission, unscrew the fitting from the slave cylinder and remove the pipe and brackets from the transmission. 4.3 TRANSMISSION DISASSEMBLE 3. Remove the 8 bolts holding the clutch housing to the transmission, then remove the housing. Figure 7B Remove the plastic vent tube (1), by pushing on the end of the tube with the flat blade of a screwdriver (2), to slide the tube from the vent tube fitting, then set the pipe to one side. Figure 7B3-56 Figure 7B3-57

39 5. Remove the 2 bolts (2) securing the clutch slave cylinder (1) to the transmission adaptor plate, then set the slave cylinder assembly (1) to one side. Figure 7B3-58 EXTENSION HOUSING 1. Install holding tool J to the front of the transmission, using 4 of the clutch housing bolts (1). 2. Install holding tool J into the bench holding fixture J With the transmission in a horizontal position with the shift lever up, drain the transmission fluid (if not carried out previously). 4. Remove the four screws securing the shift lever cover, prise the cover loose, then remove. Figure 7B3-59 Figure 7B3-60

40 5. Select either 2nd or 4th gear. 6. Remove the 4 bolts (1) holding the shifter assembly to the extension housing. If required, tap with a rubber or plastic hammer to break the seal, then remove the assembly and rubber seal from the extension housing. 7. Using a suitable pin punch (1), remove the rear offset lever roll pin (2). NOTE: Selecting 2nd or 4th gear shortens the shift rail overhang, providing more support during the roll pin removal. 8. Remove the rear offset lever (3) and check that the isolator cup (4) is secure in the lever. If loose, discard both the isolator cup and the rear offset lever. Figure 7B Remove the 8 bolts (2) holding the extension housing, noting the position of the identification tag (1). NOTE: The two top bolts (not shown) have sealant applied to the threads. Figure 7B3-62 Figure 7B3-63

41 10. With the transmission in a horizontal position, break the sealant seal by levering in the point provided, using a flat bladed screwdriver (1). 11. Tap the extension housing rearward, using a plastic or rubber hammer to remove the housing from the 2 locating dowel pins. 12. Slide the housing (3) from the shift rails (2 and 4) and remove from the transmission case (1). 13. Remove both circular magnets located in the recess in the rear of the transmission case and set to one side. Figure 7B3-64 Figure 7B3-65

42 SPEEDOMETER PULSE RING 1. Slide the sealing ring (1) from the mainshaft. 2. Using suitable snap ring pliers, remove the snap ring (2) from the speedometer pulse ring (3). 3. Assemble universal bridge puller J 8433 and puller J using bolts J , as shown. 4. Remove the speedometer pulse ring (2) from the mainshaft (1), then disassemble the tools. 5. Remove the second speedometer pulse ring snap ring, using suitable snap ring pliers. Figure 7B3-66 Figure 7B3-67 REVERSE AND 5TH/6TH DRIVEN GEAR 1. Remove the following components from the mainshaft: a. Snap ring (1). b. Spacer (2). c. Rear mainshaft roller race (3). d. Spacer (4). e. Snap ring (5). f. Thrust washer (6). g. Reverse gear (7). h. Reverse gear, caged roller bearing (8). i. Wave washer (9). j. Reverse gear blocker ring (10). Figure 7B3-68

43 2. Remove reverse synchromesh assembly snap ring (3). 3. Remove circlip (2) from the reverse shift rail and discard. 4. Remove the reverse synchromesh assembly (4), thrust washer (not shown) and reverse shift fork (1), as an assembly. NOTE: The synchromesh hub (4) is a sliding fit to the mainshaft splines. 5. Assemble universal bridge puller J 8433 and puller adaptor J using bolts J , as shown. 6. Remove 5th/6th driven gear (1), then dismantle tools. Figure 7B3-69 Figure 7B3-70

44 COUNTERSHAFT EXTENSION ASSEMBLY 1. Remove the circlip (3) from the 5th/6th shift rail, then remove the following components as an assembly; countershaft extension (1) with the 5th drive gear (2), selector fork (4) and synchromesh assembly (2), all secured by the snap ring (6). 2. Remove the following components; a. Spacer (7). b. 6th gear, blocker ring (8). c. 6th drive gear (9). d. 6th drive gear, caged needle roller bearing (10). e. Thrust washer (11). 3. Remove the 4 bolts securing the guide plate cover to the transmission case. Use a flat bladed screwdriver and plastic hammer to dislodge the cover sealant, then remove the cover. NOTE: Be careful not to bend the cover when breaking the sealant grip. 4. Remove the shift enhancer (4) from the transmission case using a suitable sized socket. 5. Using a suitable sized pin punch, remove the roll pin (3), from the front offset lever (2). Figure 7B3-71 Figure 7B3-72

45 TRANSMISSION CASE 1. Remove the two T40 Torx bit screws securing the shift lever guides (1). NOTE: Both of these screws have thread sealant applied and will be extremely difficult to remove unless a hot air gun is used to soften the thread sealant prior to loosening and during removal. 2. Remove the reverse lamp switch from the side of the transmission case. 3. Remove the 10 adaptor plate to transmission case bolts from the front of the transmission (not shown). 4. Carefully rotate the transmission into a vertical position, then lever the transmission case (2) from the adaptor plate (3), using a flat bladed screwdriver (4) in the space provided, to break the sealant seal and clear the two dowel pins. 5. Lift the transmission case upward from the gear train and shift rail components, while supporting the front offset lever during the process. NOTE: Holding the front offset lever against the guide plate during case removal, will reduce the possibility of the detent ball and spring from being dislodged. 6. Referring to Figure 7B3-70, use a T40 Torx bit, to remove the 2 screws (1) from the guide plate (5). NOTE: In Figure 7B3-70, the front offset lever (2) covers the second guide plate screw. 7. Remove the guide plate (5) from the transmission case. Figure 7B3-73

46 GEAR TRAINS AND SHIFT RAILS 1. Rotate the 5th/6th and Reverse shift levers from the interlock plate (curved arrows), then lift both shift rail assemblies from the adaptor plate. 2. Lift the mainshaft and shift forks (1) to allow counter gear (2) removal. 3. Carefully lift the mainshaft assembly with the shift forks in place, from the input shaft and set to one side. 4. Lift the input shaft from the adaptor plate and set to one side. Figure 7B3-74 Figure 7B3-75

47 DISASSEMBLE 1. With the boot and dust cover removed, use a small screwdriver to remove both E clips (1). CAUTION: Wear safety glasses to avoid possible eye injury. 4.4 REMOTE CONTROL SHIFT MECHANISM 2. Tap the two pins (3) free from the bridging piece (4). These two pins are an interference fit into each of the two pivot pieces and must be replaced after removal. 3. Remove both the smaller (2) and larger (5) bushes from the bridging piece (4). Figure 7B To disassemble the front pivot assembly, unscrew the three self tapping screws (1), using a Phillips No. 2 screwdriver. 5. By grasping the remote selector pivot (4), pull the pivot (4) and seat assembly (3) from the baseplate (5). 6. Remove the O-ring seal (2) from the seat (3). 7. Separate the selector pivot (3) from the seat assembly (2) by supporting the seat assembly over the open jaws of a vice assembly, then tap the ball end of the selector pivot (3) free from the seat (2). Figure 7B3-77 Figure 7B3-78

48 8. The rear remote shifter assembly can be disassembled by first removing the four plate (3) retaining bolts (1) from the baseplate (2). 9. Remove the wave springs (4), remote shifter shaft (5) and guide (6), from the base plate (2). 10. Finally, remove the ball seat (7) and seat support ring (8) from the base plate (2). Figure 7B3-79 CLEAN AND INSPECT Clean After removing rubber insulating bushes and seal to the extension housing, thoroughly wash all components in a suitable cleaning solvent. Dry all parts with clean, dry compressed air. CAUTION: Wear safety glasses to avoid eye injury. Inspect 1. Inspect pins, bushes, ball seats and other components for wear or damage, replacing as required. 2. Inspect the O-ring seal at the front pivot assembly, the cover plate insulating rubber bushes and seal to the extension housing, for deterioration or damage, replacing as required. REASSEMBLE While reassembly is the reverse to disassembly, there are some specific procedures such as; 1. Apply 10% molybdenum disulphide grease such as Moybond GA 10 or equivalent (to Holden s Specification HN 1271) to all moving parts in the rear remote shifter assembly. 2. Reassemble all parts in the reverse order of disassembly. 3. Install the four bolts (1) securing the plate to baseplate, tightening to the correct torque specification. REAR REMOTE SHIFT LEVER COVER BOLT TORQUE SPECIFICATION Nm Figure 7B3-80

49 4. Apply NLGI No. 4 EP grease to the ball socket of the front pivot, then reassemble by tapping the front remote pivot into the plastic socket. 5. Install the O-ring seal to the socket, replacing with a new part if the original is damaged. 6. Reinstall the assembly (1) to the baseplate, install the three retaining screws and tighten securely. 7. Install the bridging piece to the two remove lever assemblies. 8. Install new bushes to the bridging piece after lubricating with NLGI No. 4 EP grease. 9. Install NEW pivot pins to each location and tap home with a hammer. NOTE: These pins are designed to be an interference fit to the front and rear remote shifter levers and not be free floating. 10. Fit new E clips (1) to secure each pin. CAUTION: Wear safety glasses to avoid eye injury. NOTE: the dust cover and boot assembly will be installed after the remote shifter assembly is installed to the transmission extension housing. Figure 7B3-81 Figure 7B3-82

50 DISASSEMBLE Mainshaft NOTE: Do not mix any synchromesh blocker rings, or any synchromesh components. 1. Remove the O-ring (1) behind the rear mainshaft bearing (2). 2. Grasp the 1st speed gear (3) and slide from the mainshaft, removing the rear tapered roller bearing (2) in the process. 3. Remove the 1st speed gear, caged needle roller bearing (4) from the mainshaft. 4.5 TRANSMISSION SUB-ASSEMBLIES 4. Remove the snap ring (1) securing the 1st/2nd synchromesh assembly (6). 5. Remove the thrust washer (2), inner cone (3), friction cone (4), and blocker ring (5) from the 1st/2nd synchromesh assembly (6). Figure 7B Install split press plates J 36513, with the flat side (side A) against the 2nd speed constant mesh gear (3). 7. Press the mainshaft (1) from the 2nd speed constant mesh gear (3) and synchromesh assembly (2). The components of the 2nd speed synchromesh unit (2nd speed blocker ring, friction cone, 2nd speed inner cone and thrust washer), will also be removed in this operation. 8. Remove the 2nd speed gear caged needle roller bearing from the mainshaft. Figure 7B3-84 Figure 7B3-85

51 9. Remove the snap ring securing the 3rd/4th synchromesh assembly. 10. Install split press plates J with the flat side against the 3rd speed constant mesh gear (3). Press the mainshaft (1) from the 3rd/4th synchromesh assembly (2). In the process, the 3rd speed constant mesh gear (3), 3rd speed blocker ring, friction cone, inner cone and thrust washer will also be removed. 11. Remove the 3rd speed gear caged needle roller bearing from the mainshaft. 12. Install split press plates J under the pilot bearing (2) installed on the nose of the mainshaft, tightening the bolts to secure. Press the bearing (2) from the mainshaft, using a suitable sized drift (1) (or socket extension). Discard the bearing. NOTE: Only remove this bearing if it is to be replaced, as damage to the bearing during the removal process will most likely occur. Figure 7B3-86 Figure 7B3-87 Input Shaft NOTE: Only remove the input shaft bearing or the pilot bearing cup, if these components are to be replaced. 1. Install split press plates J under the input shaft bearing (1), tightening the bolts to secure. 2. Press the bearing (1) from the input shaft (2). 3. Discard the removed bearing (1). Figure 7B3-88

52 4. After assembling bearing remover J to slide hammer J 23907, remove the front mainshaft bearing cup from the input shaft (1). Discard the removed bearing cup. Figure 7B3-89 Countershaft Gear NOTE: Only remove either or both of the countershaft bearing/s if replacement is required, as damage will result from the removal procedure. 1. For the rear taper roller bearing (1); a. Install press plates J under the taper roller bearing (1), tightening the bolts to secure. b. Press the bearing (1) from the countershaft gear, using a suitable size drift (2) (or socket). c. Discard the removed bearing. 2. For the front taper roller bearing; a. Install split press plates J under the front countershaft gear bearing (1), tightening the bolts to secure. b. Press the bearing (1) from the countershaft gear (3), using a suitable size drift (2) (or socket). c. Discard the removed bearing. Figure 7B3-90 Figure 7B3-91

53 Countershaft Extension 1. Remove the following components from the countershaft gear extension (7); a. 5th/6th gear shift fork (1) b. Thrust washer (may be retained on countershaft gear) (2). c. 6th speed drive gear (3). d. Synchromesh blocking ring (4). e. Caged needle roller bearing (5). f. Spacer (6). 2. Remove 5th/6th gear synchromesh assembly snap ring. 3. With the flat sides of press plates J under the 5th speed drive gear (1), press the gear and synchromesh assembly (2) from the countershaft extension shaft (3), using a suitable size drift. Figure 7B Install split press plates J under the tapered roller bearing (2), tightening the bolts to secure. 5. Press the bearing (2) from the countershaft extension, using a suitable sized drift (1) (or socket extension). Discard the removed bearing. NOTE: Only remove this bearing if it is to be replaced, as damage to the bearing during the removal process will occur. Figure 7B3-93 Figure 7B3-94

54 Synchromesh Assemblies NOTE: This operation is not recommended, unless considered to be absolutely necessary. If disassembly is required, then extreme care must be taken to identify each component and it s exact location, using liquid paper or a felt tipped pen for the purpose. All Assemblies Except Reverse Gear 1. Using a small screwdriver, remove the synchroniser springs (1 and 5). CAUTION: Wear safety glasses to avoid eye injury. 2. Note the location of the synchromesh assembly ring V mark (1) to the key location in the hub (2), then slide the ring from the hub. Figure 7B3-95 Reverse Gear Synchromesh Assembly 1. Using a small screwdriver, remove the synchroniser spring from the reverse gear side, taking care to avoid eye damage. 2. Note the location of the synchromesh assembly ring mark ( V ) to the key location in the hub, then slide the ring from the hub. 3. Remove the three keys. 4. Remove the synchromesh key retainer (1), using a pin punch through the hub key slots. Discard the retainer. 5. Remove the second synchroniser spring, using a small bladed screwdriver. Figure 7B3-96 Figure 7B3-97

55 Reverse Idler Gear 1. Using Torx bit T40, remove the three screws (1) securing the reverse idler gear shaft support plate (2). 2. Remove the support plate (2), reverse idler gear thrust washer (3), reverse idler gear (4), caged needle roller bearing (5), the second reverse idler gear thrust washer (6), and idler gear shaft (7) from the extension housing (8). Figure 7B3-98 Reverse Lockout Solenoid Assembly Refer to 3.4 REVERSE LOCKOUT SOLENOID ASSEMBLY, in this Section, for the disassembly description. Shift Rail and Fork Assemblies 1st/2nd and 3rd/4th Shift Rail Assembly 1. Rotate the selector pin (1) until the interlock plate (7) clears both shift plate links (2 and 3). 2. Slide the 3rd/4th shift fork (4) and link (2) from the shift rail (5). 3. Slide the 1st/2nd shift fork (6) and link (3) from the shift rail (5). 4. Slide the interlock plate (7) from the shift rail (5). 5. Using a suitable size pin punch and hammer, remove the roll pin (8) from the selector pin (1). NOTE: While both shift fork links are the same, it is good practice to keep each link with its respective fork. Figure 7B3-99

56 5th/6th and Reverse Shift Rail Assembly 6. Remove the roll pin (1) from the collar (2) and shift rail (3), using a suitable size pin punch and hammer. 7. Slide the 5th/6th shift rail lever (5) from the shift rail (3). NOTE 1: Only remove the bushes from the 5th/6th shift rail if they are worn or damaged and require replacement. NOTE 2: While the sleeve can be pressed from the 5th/6th shift rail lever (after removing the retaining circlip), this operation is not recommended unless parts are to be replaced. 8. Using a suitable size pin punch and hammer, remove the roll pin (4) holding the reverse shift rail lever (6) to the shift rail (3). Slide the reverse shift rail lever (6) from the shift rail (3). Figure 7B3-100 Transmission Adaptor Plate 1. Slide the input shaft bearing cup (2) and shim/s (3) by pulling with the finger tips of each hand. NOTE: Rotating the cup back and forth while pulling, will reduce the problem of the bearing cup cocking and jamming in the adaptor plate bore. 2. Repeat this process with the counter shaft front bearing cup (4) and shim/s (5). 3. Prise the input shaft oil seal (6) from the adaptor plate (1). 4. Only remove the dowel pins (7), if replacement is required. 5. Using a 3/8 drive socket bar, remove the adaptor plate plug (2) from the front of the adaptor plate (1). Figure 7B3-101 Figure 7B3-102

57 6. If worn or damaged, remove the 1st/2nd and 3rd/4th shift rail bushing (2), using the following procedure; a. Screw bushing remover J into the shift rail bushing (2). b. Screw slide hammer J into the bushing remover J and remove the bushing (2) from the adaptor plate (1). Figure 7B3-103 Transmission Case 1. Using a 3/8 drive socket bar, remove the filler plug (1) from the transmission case (2). NOTE: Only remove the rear mainshaft bearing cup (2) and/or rear countershaft gear bearing cup (3) if these components are to be replaced. 2. Press the mainshaft bearing rear cup (2) from the transmission case (1), using remover J and driver handle J Press the countershaft gear rear bearing cup (3) from the transmission case (1), using remover J and driver handle J Discard removed bearing cup/s. Figure 7B3-104 Figure 7B3-105

58 5. If worn or damaged, remove the shift rail bushes (1), using bushing remover J and a suitable driver handle (2). Discard the removed bushes. Figure 7B3-106

59 Extension Housing NOTE: If not removed during the transmission disassembly process, remove the following components; a. Drain Plug. b. Reverse lockout solenoid and body assembly. c. Vehicle speed sensor. d. Reverse idler gear assembly. 1. Slide the countershaft gear extension, rear bearing cup (1), shim/s (2) and oil funnel (3) by pulling with the finger tips of each hand. NOTE: Rotating the rear bearing cup (1) back and forth while pulling with the finger tips, will reduce the problem of the bearing cup cocking and jamming in the adaptor plate bore. 2. Prise the rear seal (4) from the extension housing, using a suitable lever. Discard the removed seal. Figure 7B3-107 NOTE: Only remove the mainshaft rear roller bearing cup if the bearing assembly is to be replaced. 3. Remove the mainshaft rear roller bearing cup retaining snap ring (1) using suitable pliers. 4. Press the mainshaft rear bearing cup (2) from the extension housing, using remover J and driver handle J If worn or damaged, remove the shift rail bushing (1), using bushing remover J and a suitable driver handle. Discard the removed bushing. Figure 7B3-108 Figure 7B3-109

60 NOTE: Only remove the propeller shaft slip yoke bush, it replacement is required. 6. If the extension oil seal has not been removed, then refer to step 2 in this service operation. 7. Using Tool No. 7AT5 and driver handle 7AT2 (or equivalent), press bush from housing. Figure 7B3-110 CLEAN AND INSPECT COMPONENTS Clean Thoroughly wash all components in a suitable cleaning solvent. Dry all parts with clean, dry compressed air. CAUTION: Wear safety glasses to avoid eye injury. Use a wire brush or thread taps to clean thread sealant from all fasteners that are to be re-used. Inspect 1. Inspect transmission case, rear extension, adaptor plate and clutch housings for any cracks or defects that may cause lubricant leakage. 2. Ensure that there is no damage to or sealant on, the front face of transmission adaptor plate that could cause misalignment between case and clutch housing. 3. Check all machined faces for burrs and traces of sealant. If scraping of theses surfaces is required, only use a plastic scraper to avoid damaging finely machined alloy surfaces. If burrs are found, dress them off with a fine mill file. 4. All roller and needle bearing assemblies should be inspected closely and replaced if there is any sign of wear. Inspect mainshaft and internal surfaces of all gears where needle bearings come in contact. For diagnosis of tapered roller bearing failures, refer to 4.3, 'DIFFERENTIAL AND REAR AXLE BEARING DIAGNOSIS' in Section 4B, REAR AXLE of the VT Series I Service Information. NOTE 1: If the countershaft gear bearings are worn or damaged, refer to 4.5 TRANSMISSION SUB-ASSEMBLIES, Disassemble, Countershaft Gear, in this Section. If either bearing is removed, it must be replaced with a new part as damage will occur during the removal operation. NOTE 2: If the input shaft bearing is worn or damaged, refer to 4.5 TRANSMISSION SUB- ASSEMBLIES, Disassemble, Input Shaft, in this Section.

61 NOTE 3: As needle roller wear can be difficult to see, it is good practice to replace all needle roller bearings where the vehicle has travelled a substantial distance. 5. Inspect all gears, sleeves, hubs, rings and shafts for wear, scoring, pitting, chips, nicks or burrs. Slight scores or burrs may be honed off with a fine stone but, if a gear is chipped or unduly worn, it must be replaced. 6. Check synchroniser teeth on blocking rings and gears. Replace any component that is worn or damaged. 7. Inspect synchroniser hubs, outer rings, inserts and springs for damage or wear. Check that the synchroniser rings slide freely on their hubs. Replace any worn component. NOTE: Even though the synchromesh blocking rings are the same, it is sound practice to keep each ring with its respective gear, to preserve wear patterns. 8. Inspect reverse idler gear shaft, replacing if worn. 9. Check all thrust washers, replace any that are worn. 10. Inspect all shift control component, both contact and sliding surfaces for wear, scratches, projections or other damage. 11. Inspect breather tube to ensure that it is not blocked. 12. Measure the wear of all blocker rings as follows: a. Place the three blocking ring components onto the appropriate gear cone i.e. fifth gear blocking ring assembly onto fifth speed drive gear. b. Hold rings square on the gear s cone surface and hold firmly in the seated position. c. Measure clearances in the location shown. d. Discard any blocker ring that measures less than the minimum prescribed clearance. BLOCKER RING ASSEMBLY TO GEAR CLEARANCE 1st to 6th GEARS INCLUSIVE mm Minimum REVERSE mm Minimum Figure 7B3-111

62 REASSEMBLE Synchromesh Assemblies All Assemblies 1. Install the synchromesh ring over the hub, aligning the V on the edge of the ring (1) with one of the hub key openings (2). NOTE: While each of the hubs has no offset, the orientation of the outer synchroniser ring is specific, depending on the application. 2. Install the three keys (1) with the protrusions facing outward. 3. Install one synchroniser spring (2), locating the spring tang in one of the synchroniser keys, using a small screwdriver to assist. CAUTION: Wear safety glasses to avoid eye injury. 4. Turn the assembly over, then install the second synchroniser spring (3), locating the tang in the same key as before but in the opposite direction to the first. Again use a small screwdriver to assist. NOTE: The synchromesh assembly is shown in an exploded state to more clearly show the synchroniser spring arrangement. Figure 7B3-112 Reverse Synchromesh Assembly Only 1. Install a NEW synchromesh key retainer (1), locating the tangs over the synchromesh keys. 2. Using a suitable size sleeve such as Tool 3A8-6 (or tube I.D. 50 mm, wall thickness 5 mm maximum) and a hammer, install the key retainer, securing it to the synchromesh hub centre. Figure 7B3-113 Figure 7B3-114

63 Mainshaft 1. With press plates J installed under the mainshaft flange as shown, press a NEW spigot taper roller bearing (2) onto the mainshaft (3), using a suitable sleeve (1) (e.g. 21 mm socket). 2. With press plates J , still installed under the mainshaft flange, install the 3rd gear caged needle roller race, 3rd gear (1) and the blocker ring (2). 3. Install plastic sleeve (3) over the mainshaft. Figure 7B Install 3rd/4th synchromesh assembly (2) to the mainshaft splines, noting that the groove in the outer ring faces forward (to 4th gear). 5. Press 3rd/4th synchromesh assembly to the mainshaft, using a suitable size sleeve (3) (47 mm ID, minimum length 25 mm and wall thickness 5 mm). 6. During the pressing process, hold the 3rd gear (1) and blocker ring into place against the synchromesh assembly (2) to ensure correct location of the locating dogs on the blocker ring, with the synchromesh keys. Figure 7B3-116 Figure 7B3-117

64 7. Install 2nd speed gear (3) and caged needle roller bearing, the blocking ring and 1st/2nd speed synchromesh assembly (2) to the mainshaft, noting that the groove in the outer ring of the synchromesh assembly faces rearward (to 1st gear). 8. Using a suitable sleeve such as Tool 3A8-6 (1) (or I.D. 50 mm, wall thickness 5 mm), supported by press plates J as shown, press the mainshaft into the 1st/2nd speed synchromesh assembly (2). NOTE: The locating dogs of the 2nd speed blocking ring should be aligned with the synchromesh keys during the pressing process, allowing the 2nd speed gear (3) weight to keep the assembly in place. Figure 7B3-118 Input Shaft 1. Use tube 4A24 or equivalent size (O.D. 47 mm, length approximately 40 mm) and an hydraulic press to install a new input shaft bearing cup into the counter bore of the input shaft (1). 2. Using a suitable size tube (1) (I.D. 32 mm, wall thickness 5 mm maximum and length 200 mm), and an hydraulic press, install a new tapered roller bearing (2) to the input shaft (3). Figure 7B3-119 Figure 7B3-120

65 Countershaft Gear 1. Using press plates J , support the input gear of the countershaft gear (1). 2. Install a new bearing (2) to the small end of the countershaft gear (1), using a suitable size sleeve (3) (I.D. 40 mm, wall thickness 4 mm maximum) and an hydraulic press. 3. Using press plates J , support the input gear of the countershaft gear (1) as shown. 4. Install a new bearing (2) to the large end of the countershaft gear (1), using installer J 5590 or a suitable sleeve (I.D. 36 mm, wall thickness 4 mm maximum) and an hydraulic press. Figure 7B3-121 Figure 7B3-122

66 Countershaft Extension Gear 1. With press plates J installed under the countershaft extension flange (1) as shown, press a NEW taper roller bearing (2) onto the extension (1), using a suitable sleeve (3) (e.g. 21 mm socket). 2. Install the following components to the countershaft extension (1): a. 5th gear caged needle roller bearing (2). b. 5th speed drive gear (3). c. 5th speed synchromesh blocking ring (4). d. 5th/6th speed synchromesh assembly (5). Figure 7B With the assembly arranged as shown, press the countershaft extension into the synchromesh assembly hub, using tube J NOTE: Index the blocking ring assembly with the synchromesh keys before pressing operations. 4. Fit a NEW snap ring to the countershaft extension to secure the synchromesh assembly. Illustration Key: 1. Countershaft gear extension. 2. 5th speed drive gear. 3. 5th/6th speed synchromesh assembly. Figure 7B3-124 Figure 7B3-125

67 5. Install the spacer washer (6), caged needle roller bearing (5), 6th speed blocking ring (4), 6th speed drive gear (3), and thrust washer (2) with the recessed side facing the countershaft gear. 6. Install the 5th/6th shift fork (1) to the synchromesh ring, in preparation for installation. Figure 7B3-126 Reverse Idler Gear 1. Install the reverse idler gear shaft (7) and thrust washer (6) to the transmission extension housing (8). 2. Lubricate the reverse idler gear (4) and caged needle roller bearing (5) with clean transmission fluid, then install both over the idler gear shaft (7). 3. Install the outer thrust washer (3) and reverse idler shaft retaining bracket (2). 4. After cleaning any thread sealant residue from the threads of the three, Torx headed bracket screws (1), apply thread sealant such as Loctite 242 or equivalent (to Holden s Specification HN 1256 Class 2, Type 2), to the screw threads. Install and tighten the screws to the correct torque specification. REVERSE IDLE GEAR SHAFT BRACKET SCREW TORQUE SPECIFICATION Nm Figure 7B3-127

68 Reverse Lockout Assembly Refer to 3.4 REVERSE LOCKOUT SOLENOID ASSEMBLY, in this Section, for the reassembly description. Shift Rail and Fork Assemblies 1st/2nd and 3rd/4th Shift Rail Assembly 1. If removed, slide the selector pin (1) over the shift rail (5) and secure with a new roll pin (8). 2. Install the interlock plate (7) over the selector pin (1), then slide the 1st/2nd shift fork (6) and link (3) over shift rail (5), rotating the interlock plate to allow installation of the link (3). 3. Repeat step 2 for the 3rd/4th shift fork and link (2). 4. Rotate the interlock plate (7) to engage both shift fork links (2 and 3). 5th/6th and Reverse Shift Rail Assembly 1. Using a suitable size pin punch and hammer, install a NEW roll pin (4) to secure the reverse shift rail lever (6) to the shift rail (3). 2. Slide the 5th/6th shift rail lever assembly (5) onto the shift rail (3). 3. Using a suitable size pin punch and hammer, install a new roll pin (1) to secure the collar (2). Figure 7B3-128 Figure 7B3-129 Transmission Adaptor Plate 1. If removed, install a new shift rail bush (2) to the adaptor plate (1), using installer J or equivalent stepped driver. Figure 7B3-130

69 2. Install both the input shaft and front countershaft bearing cups (2 and 3 respectively) to the adaptor plate (1), WITHOUT any shims. The correct shim thickness will be fitted during the assembly operations, when shaft end floats are determined. Figure 7B3-131 Transmission Case 1. If removed, install new shift rail bushes (1) to the transmission case (2), using installer J or equivalent stepped driver. 2. Install mainshaft bearing cup (3) and countershaft bearing cup (4), using installer J39435 and driver handle J If removed, install new dowel pins. 4. Loosely install filler plug. Figure 7B3-132 Extension Housing 1. If removed, install new shift rail bushing (1) to the extension housing (2), using tool J or equivalent stepped driver. 2. Install mainshaft roller bearing cup (3), using installer J39546 and driver handle J Install roller bearing cup circlip (4), using suitable pliers. Figure 7B3-133

70 4. If required, install a new propeller shaft slip yoke bush (1) to the extension housing (2), using Tool No. 7AT5 and driver handle 7AT2 (or equivalent), taking note of the following points; a. Align the split join in the bush with the bottom of the extension housing bore. b. Install the bush (1) to a depth of 18 mm (distance A ), measured from the end of the extension housing (2) to the end of the bush. 5. Temporarily install the countershaft extension bearing cup (1) WITHOUT any shims. Shim selection will be determined during the end float measuring procedure detailed in 4.6 BEARING SHIMMING PROCEDURES. 6. Apply sealant such as Loctite 565 or equivalent (GM P/N ), to the cleaned threads of the transmission drain plug (2) and install, tightening to the correct torque specification. TRANSMISSION DRAIN PLUG TORQUE SPECIFICATION Nm Figure 7B3-134 Figure 7B3-135

71 INPUT SHAFT/MAINSHAFT & COUNTERSHAFT 1. With the adaptor plate mounted to the transmission holding fixture J that in turn, is installed into bench fixture J , rotate to the vertical with the rear of the adaptor plate facing up. 2. Install the input shaft, 4th speed blocking ring and mainshaft into the front bearing cup. Check that the blocker ring is correctly aligned with the synchromesh assembly keys. 3. While slightly lifting the mainshaft, install the countershaft to its front bearing. 4.6 BEARING SHIMMING PROCEDURES 4. Install the transmission case to the adaptor plate and install the eight adaptor plate to case bolts. 5. Tighten the eight bolts to the correct torque specification. ADAPTOR PLATE TO TRANSMISSION CASE TORQUE SPECIFICATION Nm 6. Rotate the assembly through 180 and mount a commercially available dial indicator (1) and stand (2) to the end of the transmission case (3), as shown. Zero the dial indicator, then lift the mainshaft (4) up and down to obtain the end play. 7. Select a shim pack to achieve the correct bearing pre-load specification. INPUT SHAFT/MAINSHAFT PRE-LOAD SPECIFICATION mm NOTE: There are 37 shim selections available, ranging from mm. 8. Remove the dial indicator assembly. Figure 7B3-136 Figure 7B3-137

72 9. With the transmission assembly remaining in the vertical position, mount a commercially available dial indicator (1) to the transmission case (2), with the probe sensing the end of the countershaft (3). Zero the dial indicator. 10. Insert countershaft end play rod J into the adaptor plate plug hole, then use the rod to move the countershaft up and down, enabling an end play measurement to be taken. 11. Select a shim pack to achieve the correct bearing pre-load specification. COUNTERSHAFT PRE-LOAD SPECIFICATION mm NOTE: There are 33 shim selections available, ranging from mm. 12. Remove the dial indicator assembly. Figure 7B3-138

73 COUNTERSHAFT EXTENSION Important: This procedure is not to be undertaken until the correct shim stack has been installed under the countershaft front bearing cup. 1. Loosen then remove the adaptor plate to transmission case bolts. 2. Lift the transmission case clear of the mainshaft and countershaft. 3. Lift the mainshaft slightly to allow countershaft removal. 4. Remove the mainshaft assembly, then lift the input shaft and blocking rings from the adaptor plate. 5. Remove the input shaft bearing cup, by pulling with the finger tips of each hand. NOTE: Rotating the bearing cup back and forth while pulling, will reduce the problem of the bearing cup cocking and jamming in the adaptor plate bore. 6. Repeat this process with the counter shaft front bearing cup. 7. Install the calculated shim stack for the input shaft/mainshaft and countershaft, previously determined. 8. Reinstall the input shaft and countershaft bearing cups. 9. Reinstall the input shaft, 4th speed blocking rings and mainshaft, to the adaptor plate, ensuring that the blocking rings engage correctly with the synchromesh assembly keys. 10. Reinstall the countershaft to the adaptor plate, using the same procedure detailed previously. 11. Reinstall the transmission case over the mainshaft, install the eight adaptor to transmission case bolts and tighten to the correct torque specification. ADAPTOR PLATE TO TRANSMISSION CASE TORQUE SPECIFICATION Nm 12. With the transmission in a vertical position, install the countershaft extension, ensuring that the recessed side of the thrust washer faces toward the countershaft and that the dogs on the extension fully engage with those on the countershaft. 13. Install the extension housing over the countershaft extension, install the eight bolts and tighten to the correct torque specification. Figure 7B3-139

74 EXTENSION HOUSING TO TRANSMISSION CASE BOLT TORQUE SPECIFICATION Nm 14. Insert countershaft extension, end play rod J through the adaptor plate plug hole and hollow countershaft, then screw the rod into the threaded end of the countershaft extension. 15. Mount a commercially available dial indicator to the adaptor plate, with the probe sensing the end of the end play rod. Zero the dial indicator. 16. Lift the end play rod J up and down to determine the countershaft extension end play. 17. Select a shim pack to achieve the correct end play specification. COUNTERSHAFT EXTENSION END PLAY SPECIFICATION mm NOTE: There are 33 shim selections available, ranging from mm. 18. Remove the dial indicator and end play rod. 19. Apply sealant such as Loctite 565 or equivalent (GM P/N ), to the cleaned threads of the adaptor plug, install the plug and tighten to the correct torque specification. ADAPTOR PLATE PLUG TORQUE SPECIFICATION Nm 20. Loosen then remove the eight extension housing to transmission case bolts, then remove the extension housing. 21. Slide the countershaft gear extension, rear bearing cup (1) from the extension housing. NOTE: Rotating the cup back and forth while pulling with the finger tips, will reduce the problem of the bearing cup cocking and jamming in the adaptor plate bore. 22. Install the oil funnel (3), the shim pack determined from the end play check (2), then reinstall the countershaft extension rear bearing cup (1). Figure 7B Loosen then remove the eight adaptor plate to transmission case bolts, then remove the transmission case. 24. Lift the mainshaft assembly slightly to allow countershaft removal, then remove the mainshaft assembly and input shaft and blocker rings. Figure 7B3-141

75 GEAR TRAINS AND SHIFT RAILS 1. Using seal installer J 39433, install a new oil seal (1) to the adaptor plate (2). 2. Lubricate the input shaft, taper roller bearing and seal contact area of the input shaft with clean transmission fluid, then reinstall the input shaft to the adaptor plate. 3. Install the blocker rings to the input shaft gear. 4.7 TRANSMISSION REASSEMBLE 4. Reinstall the mainshaft, together with the 1st/2nd, 3rd/4th shift shaft and forks (1) after lubricating the spigot taper roller bearing and shift shaft bush with clean transmission fluid. Take care that the 4th speed blocker rings are correctly engaged with the synchromesh assembly keys. 5. Lubricate the countershaft, front and rear taper roller bearings with clean transmission fluid, then reinstall the countershaft (2) to the adaptor plate, after lifting the mainshaft assembly (1) slightly, to allow installation access. Figure 7B3-142 Figure 7B3-143

76 6. Install the 5th/6th and Reverse shift shaft assembly, then align the slots in the shift rail levers with the interlock plate and selector pin. Figure 7B3-144

77 TRANSMISSION CASE 1. Install the front offset lever guide plate to the transmission case, install the two Torx headed screws and tighten to the correct torque specification, using a T40 Torx bit and adaptor. SHIFT GUIDE PLATE SCREW TORQUE SPECIFICATION Nm NOTE: The H pattern in the guide plate must face the rear of the transmission. i.e. to the extension housing. 2. Apply a single bead of sealant such as Loctite Ultrablack 598 or equivalent (GM P/N ), to the cleaned, transmission case to adaptor plate mating surface. 3. Reinstall the transmission case (2) over the mainshaft and shift shaft. As the case is installed, push the front offset lever against the detent ball and spring, holding the detent ball against the guide plate, in the neutral plane position, to align the front offset lever with the shift shaft. 4. When the case is fully installed over the two adaptor plate dowel pins, install the eight adaptor to transmission case bolts and tighten to the correct torque specification. ADAPTOR PLATE TO TRANSMISSION CASE TORQUE SPECIFICATION Nm 5. Apply thread sealant such as Loctite 242 or equivalent (to Holden s Specification HN 1256 Class 2, Type 2), to the cleaned threads of the shift lever guide bolts (1), install and tighten to the correct torque specification. SHIFT LEVER GUIDE BOLT TORQUE SPECIFICATION Nm NOTE: It might be necessary to pull up on the 5th/6th and Reverse shift shaft to align the slot of the interlock plate with the guide bolt hole. Important: to maintain the shift rails in the correct position during the remainder of the assembly process, it is vital that these two guide bolts are installed at this time. Figure 7B3-145

78 6. Align the front offset lever (2) with the hole in the shift shaft, then install a new roll pin (3) to secure, using a suitable size pin punch and hammer. NOTE: Insert a pin punch of suitable size into the rear offset lever roll pin hole in the shift shaft and check that the shift shaft is able to be rotated freely through each of the detent ball positions. This will ensure that the shift selector forks, interlock plate and associated parts are all aligned correctly. If difficulty is experienced in rotating the shift shaft, then the transmission case must be removed and the problem rectified before proceeding. 7. Apply thread sealant such as Loctite 242 or equivalent (to Holden s Specification HN 1256 Class 2, Type 2), to the cleaned threads of the shift enhancer (4), then, using a 24 mm socket, install and tighten to the correct torque specification. SHIFT ENHANCER TORQUE SPECIFICATION Nm 8. Apply a continuous bead of sealant such as Loctite Ultrablack 598 or equivalent (GM P/N ), to the mating surface of the cover plate, then install to the transmission case. 9. Install the four cover bolts and tighten to the correct torque specification. FRONT OFFSET LEVER COVER BOLT TORQUE SPECIFICATION Nm 10. Install the back-up lamp switch and tighten to the correct torque specification. BACK-UP LAMP SWITCH TORQUE SPECIFICATION Nm Figure 7B3-146

79 COUNTERSHAFT EXTENSION ASSEMBLY 1. Install the following components to the countershaft extension (5); a. Spacer (7). b. 6th gear, blocker ring (8). c. 6th drive gear (9). d. 6th drive gear, caged needle roller bearing (10). e. Thrust washer (11). NOTE 1: Ensure that the recessed side of the thrust washer (11) faces the countershaft. NOTE 2: Snap ring (6) was installed when the 5th/6th synchromesh assembly (2) was installed to the countershaft extension (1). Refer page 7B With the 5th/6th shift fork (4) positioned as shown, install the countershaft extension assembly onto the rear of the countershaft, guiding the 5th/6th shift fork (4) over the 5th/6th shift rail lever sleeve. 3. Rotate the countershaft extension back and forth to ensure that the dog teeth on the countershaft extension mate with the corresponding dogs on the end of the countershaft. 4. Install a new circlip (3) to the groove in the 5th/6th shift rail lever sleeve to secure the shift fork. Figure 7B TH/6TH DRIVEN GEAR 1. Install the 5th/6th speed driven gear (1) over the mainshaft with the smaller gear facing inward. 2. Engage the inner gear splines with those on the mainshaft and install, using installer J and bolt/nut J NOTE: It may be necessary to rotate the 5th and 6th drive gears on the countershaft extension to assist in gear meshing with the driven gear (1), prior to the gear installation process. Figure 7B3-148

80 REVERSE SYNCHROMESH ASSEMBLY 1. With the reverse shift lever (1) positioned as shown, install the reverse synchromesh assembly (4) and shift lever (1) to the mainshaft and shift shaft, ensuring that the reverse synchromesh key retainer faces the end of the 6th speed driven gear. 2. Fit a new circlip (2) to retain the shift fork (1) and a new snap ring (3) to secure the reverse synchromesh assembly (4). Figure 7B3-149 REVERSE SPEED GEAR 1. Install the following components onto the mainshaft, aligning the blocker rings with the synchromesh keys, in the process; a. Reverse gear blocker ring (10). b. Wave washer (9). c. Reverse gear, caged roller bearing (8). d. Reverse gear (7). e. Thrust washer (6). 2. Fit a new snap ring (5) to secure the reverse driven gear (7). 3. Continue to install the components of the rear mainshaft roller bearing, as follows; a. Spacer (4). b. Rear mainshaft roller race (3). c. Spacer (2). 4. Secure these components with a new snap ring (1). Figure 7B3-150

81 SPEEDOMETER PULSE RING 1. Install a new, inner snap ring to the speedometer pulse ring groove in the mainshaft. 2. Install the speedometer pulse ring to the mainshaft, using Installer J and bolt/nut J Tighten the nut of J until the pulse ring bottoms against the snap ring. 4. Remove the tools. 5. Install a new snap ring (2) to the outer speedometer pulse ring (3) groove in the mainshaft. 6. Slide a new sealing ring (1) onto the mainshaft. Figure 7B3-151 Figure 7B3-152

82 EXTENSION HOUSING 1. Rotate the transmission through 90 into the horizontal position, then move the shift rail (4) into the 2nd or 4th gear position to shorten the shift rail length. 2. Lubricate the countershaft extension taper roller bearing with clean transmission fluid. 3. Install the two circular magnets into the grooved space in the transmission case. 4. Apply a continuous bead of sealant such as Loctite Ultrablack 598 or equivalent (GM P/N ), to the extension housing to transmission case mating surface. 5. Install the extension housing (3) over the mainshaft, aligning the shift rails (4 and 2) with the extension housing bushes. NOTE: Because the 5th/6th and Reverse shift shaft is unsupported at this point, it will need to be manipulated to align the end of the shaft with the corresponding bore in the extension housing. Do not try and force the extension housing over the dowel pins. Figure 7B Install all but the two upper extension housing bolts. (not shown). Apply thread sealant such as Loctite 565 or equivalent (GM P/N ), to the cleaned threads of the two upper bolts. Note that a wiring harness clip is under the right hand upper bolt and also, the position of the identification tag (1). 7. Tighten all 8 bolts (2) to the correct torque specification. EXTENSION HOUSING BOLT TORQUE SPECIFICATION Nm 8. Install the O-ring to the reverse lockout solenoid assembly, then install the assembly and retaining bolt to the extension housing, tightening to the correct torque specification. REVERSE LOCKOUT SOLENOID BOLT TORQUE SPECIFICATION Nm 9. Install the O-ring seal to the speedometer sensor, then install the sensor to the extension housing, retaining with a screw, tightened to the correct torque specification. SPEED SENSOR RETAINING SCREW TORQUE SPECIFICATION Nm Figure 7B3-154

83 10. Using seal installer J 39440, install a NEW rear seal to the extension housing. 11. Slide the rear offset lever (3) over the shift rail and secure with a new roll pin (2), installed with a suitable pin pinch (1) and hammer. 12. Apply Lithium grease NLGI No. 4 EP to the isolator cup (4) in the rear offset shift lever (3). Figure 7B If the remote shifter assembly, rubber seal is undamaged, then it may be re-used. Otherwise, fit a new seal to the extension housing. 14. Install the remote shifter assembly to the extension housing, install the insulating grommets and four retaining bolts (1), then tighten to the correct torque specification. REMOTE SHIFTER RETAINING BOLT TORQUE SPECIFICATION Nm Figure 7B3-156 Figure 7B3-157

84 15. Install the cover over the remote shifter assembly and secure with the 4 screws (1). Do not over-tighten. Figure 7B3-158

85 CLUTCH HOUSING AND SLAVE CYLINDER 1. Remove the transmission from the transmission holding fixture J Install the 10 clutch housing and bolts, tightening to the correct torque specification. CLUTCH HOUSING TO ADAPTOR PLATE BOLT TORQUE SPECIFICATION Nm 3. Install the clutch slave cylinder (1) over the input shaft. 4. Apply thread sealant such as Loctite 242 or equivalent (to Holden s Specification HN 1256 Class 2, Type 2), to the two slave cylinder retaining bolts (2), install and tighten to the correct torque specification. CLUTCH SLAVE CYLINDER BOLT TORQUE SPECIFICATION Nm Important: Before tightening the two retaining bolts, centralise the slave cylinder bleeder screw in the transmission adaptor plate/clutch housing aperture. This is necessary to ensure access to the bleeder, after the transmission has been installed. 5. Sparingly apply 10% molybdenum disulphide grease, such as Molybond GA 10 (or equivalent to Holden s Specification HN 1271) to the clutch throwout bearing contact face, the splines and spigot of the input shaft. Figure 7B3-159 Figure 7B Route the clutch fluid pipe around the transmission housing, install the bracket fasteners (1) and tighten to the correct torque specification. CLUTCH PIPE BRACKET SCREW TO LEFT HAND SIDE TORQUE SPECIFICATION CLUTCH PIPE BRACKET SCREW TO RIGHT HAND SIDE TORQUE SPECIFICATION Nm Nm Figure 7B3-161

86 7. Install the clutch fluid pipe fitting (1) to the slave cylinder (2) and tighten to the correct torque specification. CLUTCH FLUID PIPE FITTING TO SLAVE CYLINDER TORQUE SPECIFICATION Nm 8. Install the transmission vent tube (1), sliding it over the pipe located at the front offset lever. Figure 7B If removed, install the rear engine mount to transmission extension bolts, tightening to the correct torque specification. TRANSMISSION MOUNT TO EXTENSION HOUSING BOLT TORQUE SPECIFICATION Nm 10. Fit a suitable plug to the rear oil seal to prevent dirt/dust entry. 11. Reinstall transmission into the vehicle. Refer to 4.2 TRANSMISSION ASSEMBLY, in this Section. 12. Fill transmission with 3.9 litres of Dexron III fluid (to Holden s Specification HN 2126). 13. Apply sealant such as Loctite 565 or equivalent (GM P/N ), to the cleaned threads of the filler plug and tighten to the correct torque specification. FILLER PLUG TORQUE SPECIFICATION Nm NOTE: Under no circumstances is Teflon thread tape to be used on the filler, drain or adaptor plate plugs. Figure 7B3-163

87 5. DIAGNOSIS 5.1 TRANSMISSION SHIFTS HARD DEFINITION: The transmission does not shift smoothly or without difficulty into another gear. Step Action Value(s) Yes No Check the transmission for improper lubricant. Refer to 2.1 Recommended Lubricant. Is the recommended lubricant being used? Check the transmission for loose shift lever housing bolts. Are the bolts loose? Drain and refill the transmission with the recommended lubricant. Refer to 2.3 DRAINING AND REFILLING TRANSMISSION. Does the transmission shift smoothly? Align the component parts and tighten the fasteners. Refer to 7. TORQUE SPECIFICATIONS. Does the transmission shift smoothly? Check for proper clutch operation. Was the clutch the cause of hard shifting? 1. Remove the transmission. Refer to 4.2 TRANSMISSION ASSEMBLY, Remove. 2. Disassemble the transmission. Refer to 4.3 TRANSMISSION DISASSEMBLE. 3. Look for the following list of causes: Binding shift rail. Mispositioned shift selector arm roll pin. Worn shift rail bores. Distorted oil seal. 4. Replace all worn or damaged parts. Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 System OK Go to Step 5 System OK Go to Step 5 System OK Go to Step 6

88 5.2 TRANSMISSION HARD TO SHIFT INTO REVERSE DEFINITION: The transmission does not shift smoothly into reverse gear or will not shift into reverse gear. Step Action Value(s) Yes No 1. Turn the ignition switch to the ON position Check for voltage at the reverse lockout solenoid electrical connector. 12 volts Is there voltage at the connector. Go to Step 2 Go to Step 5 1. Remove the reverse lockout solenoid assembly from the reverse lockout assembly. Refer to 3.4 REVERSE 2 LOCKOUT SOLENOID, Remove. 2. Apply 12 volts to the solenoid electrical connector. Is the solenoid plunger extended? Go to Step 3 Go to Step 6 Remove the reverse lockout assembly from the transmission. 3 Refer to REVERSE LOCKOUT SOLENOID ASSEMBLY, Reinstall. Can you easily depress the reverse lockout plunger with your Go to Step 4 Go to Step 7 thumb? 1. Remove the transmission. Refer to 4.2 TRANSMISSION ASSEMBLY, Remove. 2. Disassemble the transmission. Refer to 3. Look for the following list of causes: 4 Worn or broken shift linkage parts. A worn or damaged synchroniser ring or hub. 4. Replace all worn or damaged parts. 5 Repair the reverse lockout solenoid electrical circuit. Is the circuit OK? Go to Step 1 6 Replace the solenoid. Does the transmission shift OK now? System OK Repair or replace the reverse lockout assembly. Refer to REVERSE LOCKOUT SOLENOID ASSEMBLY, Replace. Does the transmission shift OK now? System OK

89 5.3 GEAR CLASH WHEN SHIFTING GEARS DEFINITION: The transmission gears clash when shifting from one gear into another. Step Action Value(s) Yes No 1 Check for low oil level in the transmission. Refer to 2.2 CHECKING TRANSMISSION LUBRICANT LEVEL. Is the oil level OK? Go to Step 2 Go to Step 3 2 Check the transmission for improper lubricant. Refer to 2.1 RECOMMENDED LUBRICANT. Is the recommended lubricant being used? Go to Step 5 Go to Step 4 3 Replenish the oil to the level of the oil fill plug Drain and refill the transmission with the recommended lubricant. Refer to 2.3 DRAINING AND REFILLING TRANSMISSION. Check for proper clutch operation. Is the clutch operating properly? 1. Remove the transmission. Refer to 4.2 TRANSMISSION ASSEMBLY, Remove. 2. Disassemble the transmission. Refer to 4.3 TRANSMISSION DISASSEMBLE. 3. Look for the following list of causes: 3.1 Gearshift components are worn or damaged. 3.2 Synchroniser assemblies worn or damaged. 4. Replace all worn or damaged parts. Go to Step 6

90 5.4 TRANSMISSION NOISY DEFINITION: Transmission gear noise in evident in the passenger compartment. Step Action Value(s) Yes No 1 Check for low oil level in the transmission. Refer to 2.2 CHECKING TRANSMISSION LUBRICANT LEVEL.. Is the oil level OK? Go to Step 2 Go to Step 3 2 Check the transmission for improper lubricant. Refer to 2.1 RECOMMENDED LUBRICANT. Is the recommended lubricant being used? Go to Step 5 Go to Step 4 3 Replenish the oil to the level of the oil fill plug. 4 Drain and refill the transmission with the recommended lubricant. Refer to 2.3 DRAINING AND REFILLING TRANSMISSION. 5 Check for loose clutch housing bolts. Refer to 7. TORQUE WRENCH SPECIFICATIONS. Are the bolts tightened to specifications? Go to Step 6 Go to Step Remove the transmission. Refer to 4.2 TRANSMISSION ASSEMBLY, Remove. 2. Disassemble the transmission. Refer to 4.3 TRANSMISSION DISASSEMBLE. 3. Look for the following list of causes: 3.1 Gearshift components are worn or damaged. 3.2 Transmission gears are worn or damaged. 3.3 Bearing components are worn or damaged. 4. Replace all worn or damaged parts. 7 Tighten the clutch housing bolts to the specified torque.

91 5.5 TRANSMISSION JUMPS OUT OF GEAR DEFINITION: Transmission selects Neutral without any driver action. Step Action Value(s) Yes No 1 Check for loose clutch housing bolts. Refer to 7. TORQUE WRENCH SPECIFICATIONS. Are the bolts tightened to specifications? Go to Step 2 Go to Step 3 2 Tighten the clutch housing bolts to the specified torque Remove the transmission. Refer to 4.2 TRANSMISSION ASSEMBLY, Remove. 2. Disassemble the transmission. Refer to 4.3 TRANSMISSION DISASSEMBLE. 3. Look for the following list of causes: 3.1 Gearshift components worn or damaged. 3.2 Gear teeth worn or tapered. 3.3 Synchroniser assemblies worn or damaged. 3.4 Excessive end play in components. 3.5 Bearing components are worn or damaged. 4. Replace all worn or damaged parts.

92 5.6 TRANSMISSION DOES NOT SHIFT INTO ONE GEAR DEFINITION: The transmission does not shift into one gear. Step Action Value(s) Yes No 1 Remove the transmission. Refer to 4.2 TRANSMISSION ASSEMBLY, Remove. Check for worn or damaged gearshift components. Go to Step 2 Go to Step 3 Are the gearshift components OK? 2 Disassemble the transmission. Refer to 4.3 TRANSMISSION DISASSEMBLE. Look for worn or damaged synchroniser assemblies. Replace all worn or damaged parts. 3 Replace the worn or damaged gearshift components. Refer to Transmission Disassemble. Will the transmission shift gears? System OK Go to Step 2

93 5.7 TRANSMISSION LOCKED IN ONE GEAR DEFINITION: The transmission cannot be shifted out of gear. Step Action Value(s) Yes No 1 Remove the transmission. Refer to 4.2 TRANSMISSION ASSEMBLY, Remove. Go to Step 2 Go to Step 3 Are the gearshift components properly assembled? 2 Are the gearshift components worn, bent or broken? Go to Step 4 Go to Step Disassemble the gearshift components. Properly assemble the gearshift components. Refer to 4.3 TRANSMISSION DISASSEMBLE. Will the transmission shift gears? Replace the worn or damaged parts. Refer to 4.3 TRANSMISSION DISASSEMBLE. Will the transmission shift gears? Disassemble the transmission geartrain. Refer to 4.3 TRANSMISSION DISASSEMBLE. Look for worn, broken, or, damaged components. Replace all worn, broken, or damaged components. System OK Go to Step 5 System OK Go to Step 5

94 TRANSMISSION: GEN III, V8 Powered Vehicles SPECIFICATIONS TRANSMISSION RATIOS: 1st :1 2nd :1 3rd :1 4th :1 5th :1 6th :1 Reverse :1 NUMBER OF TEETH: Input Gear Mainshaft Gear 1st nd rd th th Reverse Reverse Idler Gear Countershaft Gear Input Countershaft Gear 1st nd rd Countershaft Gear Extension 5th th Reverse SYNCHROMESH ASSEMBLIES: Synchromesh Ring Wear Borg Warner, Type T56 Manual Transmission. Overdrive 5th and 6th Speed, Production Option MM6. Replacement Clearance - All forward gears... less than 0.38 mm - Reverse Gear... less than 0.75 mm BEARING PRE-LOAD/END FLOAT: Input Shaft/Mainshaft mm pre-load Countershaft Gear mm pre-load Countershaft Gear Extension mm end float SELECTIVE SHIM WASHER THICKNESSES: Input Shaft Bearing mm Countershaft Gear mm Countershaft Gear Extension mm LUBRICANTS: Transmission... Dexron III fluid to Holden s Specification HN Capacity (Nominal) litres Rear Offset Lever Isolating Cup... NLGI No. 4 EP Clutch Throwout Bearing Contact Face... 10% molybdenum disulphide grease to Holden s Specification HN 1271 SEALANTS: Thread Sealant in nominated locations... Loctite 242 or equivalent (to Holden s Specification HN 1256 Class 2, Type 2) Sealing Plugs and Bumper Bolt Threads... Loctite 565 or equivalent (GM P/N ) Adaptor Plate and Extension Housing to Case Loctite Ultrablack 598 or equivalent (GM P/N )

95 7. TORQUE WRENCH SPECIFICATIONS Nm Adaptor Plate Plug Adaptor Plate to Transmission Case Bolts Backup Lamp Switch Catalytic Converter Bracket Bolt to Catalytic Converter Catalytic Converter Bracket Bolt to Transmission Extension Centre Bearing Carrier to Underbody Reinforcement Bolt Clutch Housing to Adaptor Plate Bolt Clutch Housing to Engine Block Bolt Clutch Hydraulic Pipe Bracket Bolt (LHS) Clutch Hydraulic Pipe Bracket Bolt (RHS) Clutch Hydraulic Pipe Fitting to Slave Cylinder Clutch Hydraulic Pipe Fitting to Flexible Hose Clutch Slave Cylinder Bolt Drain Plug Engine to Transmission Close-out Cover Bolts (Each Side) Extension Housing to Transmission Case Bolts Filler Plug Front Offset Lever Cover Bolts Gearshift Control Lever to Remote Shift Lever Bolt Propeller Shaft Rear Universal Joint to Pinion Flange Bolt Rear Crossmember to Transmission Support Mount Nut Rear Crossmember to Side Frame Member Bolt Rear Remote Shift Lever Cover Bolt Remote Shift Lever Cover Bolts Remote Shift Lever Boot Plate Bolt Reverse Idler Shaft Bracket Bolts Reverse Lockout Assembly Bolt Reverse Lockout Solenoid Shift Enhancer Assembly Shift Lever Guide Bolts Shift Guide Plate Bolts Speed Sensor Bracket to Extension Housing Bolt Transmission Support Mount to Extension Housing Bolt

96 8. SPECIAL TOOLS TOOL No. REF. in TEXT TOOL DESCRIPTION COMMENTS 3A8-6 SLEEVE Previously released. Also numbered E Used to install the 1st/2nd gear synchromesh hub to the mainshaft. 4A24 SLEEVE Previously released. Also numbered E1662. Used to install the bearing cup into the input shaft gear. 7AT2 DRIVER HANDLE Previously released. Also numbered E1502. Used in conjunction with 7AT5 to remove/install the slip yoke bushing in the extension housing. 7AT5 SLIP YOKE BUSH REMOVER/INSTALLER Previously released. Also numbered E1505 and J Used in conjunction with 7AT2 to remove/install the slip yoke bushing in the extension housing SEAL REMOVER Previously released. Also numbered E308 and 49V Used to remove the rear oil seal from the extension housing.

97 TOOL No. REF. in TEXT TOOL DESCRIPTION COMMENTS J BENCH HOLDING FIXTURE Previously released. Used as a bench fixture to support a transmission. J 5590 PRESS TUBE Previously released for 4L60-E automatic transmission. Used to install various components, using an hydraulic press. J 8092 UNIVERSAL DRIVER HANDLE Previously released. Used in conjunction with various other tools for removal and installation of various bearing cups in the transmission. J 8433 UNIVERSAL BRIDGE PULLER Previously released. Used in conjunction with J & 2 to remove the speedometer pulse ring and the 5th/6th speed, compound driven gear. J PRESS PLATES Previously released. Used in a number of different applications in removing bearings and other transmission components when pressing operations are required.

98 TOOL No. REF. in TEXT TOOL DESCRIPTION COMMENTS J SLIDE HAMMER Previously released. Used in conjunction with a number of different pullers to remove bushes and bearing cups in the transmission J PRESS PLATES New release. Used to press 1st/2nd speed synchromesh assembly and 2nd gear from the mainshaft. J BUSHING REMOVER New release. Used to remove the shift rail bushes in the adaptor plate and extension housing, in conjunction with slide hammer J J TRANSMISSION HOLDING FIXTURE New release. Used to mount the transmission to the bench for unit repair operations. J & 2 REMOVER AND BOLTS New release. Used to remove the speedometer pulse ring and the 5th/6th speed, compound driven gear, in conjunction with universal bridge puller J 8433.

99 TOOL No. REF. in TEXT TOOL DESCRIPTION COMMENTS J SEAL INSTALLER New release. Used to install the input shaft oil seal. J BEARING CUP INSTALLER New release. Used to install the rear mainshaft bearing cup and the rear countershaft bearing cup, in conjunction with driver handle J J BUSHING INSTALLER New release. Used to install the selector shaft bushes in the adaptor plate, and transmission case. J J BUSHING REMOVER/INSTALLER New release. Used to remove shift shaft bushes from the transmission case and extension housing. J REAR SEAL AND BOOT INSTALLER New Release. Used to install the rear extension seal.