Transmission Assemble. Chevrolet Joy 2008

For 1990-2009 cars

#### Tools Required

• | DT 46612 (DW09913-76010) Bushing, Seal Installer

• | DT 46496 (DW09940-53111) Gear, Bearing Installer

• | DT 46497 (DW09943-78210) Bushing, Seal Installer

• | DT 46553 (DW220-010A) Transaxle Fixture

• | KM-519 Oil Seal Installer

Important: Use only a new oil seal.

1. Install the input shaft oil seal using DT 46497 (1).

Important: Coat the transaxle inner parts with gear fluid when installing.

2. Install the differential right side oil seal using DT 46612 .
3. Install the oil plate with the bolts.
4. Install the oil gutter with the bolt.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the oil level plug, including the steel gasket.

Tighten
Tighten the oil level plug to 36-54 N·m (26-40 lb ft).

6. Install the left side case cap with the bolts, including the O-ring (1).

Tighten
Tighten the bolt to 8-12 N·m (71-106 lb in).

7. Install the Case cap retaining bolt.
8. Install the differential left side oil seal using KM-519 (2).
9. Install the differential assembly (1) to the right side of transaxle case. The differential ring gear surface should be lower than the right side of transaxle case surface.
10. Install the low and the high speed shift shaft assembly to the gear unit.

Important: Do NOT damage the teeth of the counter shaft pinion and the differential ring gear.

11. Push the gear unit by matching it with the input and the counter shaft hole (1).
12. Install the 5th reverse gear shift shaft.

Important: Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transaxle case - right side.

13. Install the reverse idle gear shaft assembly (2).
14. Install the reverse gear shift lever (1).

Tighten
Tighten the bolts to 18-28 N·m (13-21 lb ft).

15. Install the 3rd-4th gear shift shaft ball and spring (1).

Tighten
Tighten the bolt to 10-16 N·m (7-12 lb ft).

Important: Install the correct gear shift shaft spring that was marked when removing.

16. Install the 5th reverse gear shift shaft ball and spring (2).

Tighten
Tighten the bolt to 10-16 N·m (7-12 lb ft).

17. Coat the transaxle case with recommended Transaxle Case Sealant-THREE BOND 1215.
18. Install the transaxle left side case to the transaxle right side case bolts (1).

Tighten
Tighten the bolts to 15-22 N·m (11-16 lb ft).

19. Install the 1st-2nd gear shift shaft ball and spring.

Tighten
Tighten the bolt to 10-16 N·m (7-12 lb ft).

20. Install the reverse idle gear shaft bolt.

Tighten
Tighten the bolt to 18-28 N·m (13-21 lb ft).

Important: Check if the bearing and the outer race are correctly installed by rotating counter shaft.

21. Install the counter shaft bearing outer race using DT 46496 .
22. Measure clearance between the transaxle case surface (3) and the bearing outer race (2) using a straight ruler (1) and gage. Refer to Manual Transmission Specifications .
23. Select shim in order that clearance is within standard.

Important: Use only new screws.

24. Install the side cover plate (1).

Tighten
Tighten the screws to 6-7 N·m (53-62 lb in).

Important: Position the machined boss side toward the side cover plate.

25. Install the counter shaft 5th gear (3).
26. Shift the shift yoke using a screwdriver to engage the 1st gear and the 3rd gear or the 2nd gear and the 4th gear (3).

Tighten
Tighten the 5th gear nut to 60-80 N·m (44-59 lb ft).

27. Install the counter shaft fifth gear nut. Caulk the nut using a chisel and a hammer (2).
28. Insert the input shaft 5th gear bearing into the input shaft.
29. Install the 5th gear, wave spring and synchronizer ring matching synchronizer's oil groove and input shaft punched mark (1).

Important: When assembling the synchronizer sleeve and hub, let distance (a) equal distance (b).

30. Install the synchronizer springs to hub (1).
31. Install the synchronizer key (2).
32. Position the longer boss side of hub toward inner side (3).
33. Position the chamfered spline of sleeve toward inner side and install the hub to the sleeve (4).
34. Install the 5th gear fork to the synchronizer hub assembly.

Important: Position the longer boss side of hub toward inner side and match the synchronizer key and the hub groove with the input shaft punched mark.

35. Install the 5th gear fork and the synchronizer hub assembly to the input shaft.
36. Push the 5th gear shift fork toward the 5th gear.

Important: Use only new shift fork pin.

37. Install the 5th gear shift fork pin using a pin punch and a hammer (1).
38. Install the 5th gear synchronizer plate.
39. Install the 5th gear snap ring (1).

Important: Use only new snap ring.

40. Install the 5th gear fork snap ring (2).
41. Tighten the fork plug after inserting the guide ball into the fork hole.
42. Install the side cover (1) with recommended Side Cover Sealant-THREE BOND 1215.

Tighten
Tighten the side cover bolts to 8-12 N·m (71-106 lb in).

43. Install the gear shift control case gasket and case (1) and bolts (2).

Tighten
Tighten the bolts to 18-28 N·m (13-21 lb ft).

44. Install the shift interlock bolt.

Tighten
Tighten the shift interlock bolt to 18-28 N·m (13-21 lb ft).

45. Install the select lever.

Tighten
Tighten the bolts to 18-28 N·m (13-21 lb ft).

46. Install the backup light switch (1).

Tighten
Tighten the nut to 15-18 N·m (11-13 lb ft).

47. Install the speedometer driven gear assembly (2).

Tighten
Tighten the bolt to 4-7 N·m (35-62 lb in).

48. Install the transaxle mount (1).

Tighten
Tighten the transaxle mount nut and bolts to 55-65 N·m (41-48 lb ft).

49. Install the related clutch parts. Refer to Clutch, Pressure Plate, and Pilot Bearing Replacement .
50. Remove the transaxle assembly from the DT 46553 (1).
51. Install the transaxle assembly. Refer to Transmission Replacement .