M/T - Difficult Shifting or Gear Clash
Number: 84-109Section: 7B (VIIb)
Date: April, 1984
Subject: DIFFICULT SHIFTING OR GEAR CLASH
Model and Year: 1983-84 CAVALIER WITH
FIVE SPEED TRANSAXLE
TO: ALL CHEVROLET DEALERS
This cancels and supercedes Chevrolet Dealer Service Technical Bulletin 83-T-58 dated December, 1983 which should destroyed.
Some comments of difficult shifting into 1st or 2nd and gear clash when upshifting into 2nd or 3rd on 1983-84 Cavaliers with five speed manual transmissions have been received. This may be caused by input shaft bearing preload. If the clash does not occur with a fast shift, or disappears when the transmission warms up, the condition is very likely caused by input shaft bearing preload.
These conditions can be corrected by reducing the input shaft shim thickness. In December of 1982, production began using a reduced shim of .04. These transaxles are identified by a green dab on the rear cover.
These conditions can usually be corrected without removing the transaxle from the vehicle, in the following manner:
1. Raise vehicle on a frame hoist - leave transmission in gear.
2. Remove the left front wheel.
3. Remove inner fender plastic splash shield.
4. Remove transmission rear cover and gasket shown on Page 13 of Shop Manual, Section 76 mm Manual Transaxle. It may be necessary to bend the sheet metal slightly.
5. Remove shifter fork pin.
6. Remove nut from end of output shaft - impact wrench works best.
7. Remove synchronizer and fork together with needle rollers.
8. Remove nut on end of input shaft.
9. Remove gear and rear plate. Bearing and shim pack will be exposed.
INPUT SHAFT SHIM:
10. Remove input shaft shim.. Replace with a shim that is the minimum thickness without causing axial movement of the input shaft.
11. On reassembly, apply Loctite or equivalent to input and output shaft nuts. Also stake bearing retainer to transaxle case screws (P/N 94248159).
There should be no input shaft axial movement after rear plate is replaced. Procedure may be repeated, if necessary, as long as the input shaft does not become loose. Below is a list of shim part numbers and their thickness:
M200 INPUT SHAFT SHIMS
P/N Thickness
94115571 1.00 mm
94115572 1.08 mm
94115573 1.16 mm
94115574 1.24 mm*
94115575 1.32 mm*
94115576 1.40 mm*
94115577 1.48 mm*
94115578 1.56 mm*
94115579 1.64 mm*
94115580 1.72 mm
94115581 1.80 mm
94115582 1.88 mm
94115583 1.96 mm
94115584 2.04 mm
94115585 2.12 mm
94115586 2.20 mm
94115587 2.28 mm
94115588 2.36 mm
94115589 2.44 mm
*Most commonly used shims.
Labor Operation Number: T0121
Labor Time : 1.1 hrs.
NOTICE: Item #47 is the input shaft bearing shim. The service manual incorrectly identifies it as the output shaft bearing shim.