I. Extension Housing

DISASSEMBLE

^ Tools Required:
- J 8092 Drive Handle
- J 39439-1 Bushing Remover
- J 39440 Rear Boot and Seal Installer
- J 39546 Beating Race Installer
- J 39789 Bearing Race Remover
- J 39437 Bushing Installer
- J 41099 Reverse Solenoid Socket

1. Reverse idler shaft bracket bolts (133).
2. Reverse idler shaft bracket (134).
3. Reverse idler gear (136).
4. Roller bearings (137).
5. Reverse idler shaft (138).
6. Countershaft extension bearing race (130).
7. Shim (131).
8. Funnel (132).
9. Plug (101).
10. Reverse lockout assembly bolt (90).

CAUTION: The reverse lockout assembly is under spring pressure. Exercise caution when removing snap ring (173), as bodily injury may result.

11. Reverse lockout assembly (91).
A. Reverse lockout solenoid (89) from reverse lockout body (175) using J-41099.
B. O-ring seal (160) from body (175).
C. Snap ring (169) from body (175).
D. Reverse lockout inner spring (174).
E. Compress reverse lockout plunger (170) and collar (172) in vise and remove snap ring (173).
F. Reverse lockout plunger (170).
G. Reverse lockout outer spring (171).
H. Reverse lockout collar (172).

12. Vehicle speed sensor bolt (88).
13. Vehicle speed sensor (87) and clamp.
- O-ring seal from vehicle speed sensor (87).
14. Rear seal and boot (99).
- Pry out seal and boot (99) with suitable tool.
15. Mainshaft bearing race snap ring (84).

Important
- Do not replace bearing race (85) unless inspection shows bearing race damage.

16. Mainshaft bearing race (85) using J 8092 and J 39789.

Important
- Do not replace bushing (92) unless inspection shows bushing damage.

17. Shift rail bushing (92) using J 36190 and J 39439-1.

Clean
- Extension housing components with solvent and dry with compressed air.

Inspect
Extension housing components:
- Bearing races (85 and 130) and bores for wear, scratches or grooves.
- Bushing (92) for excessive wear or burrs. Replace if these conditions exist.
- Case (86) for cracks, sealing surfaces for nicks, burrs or scratches. If case is cracked, it must be replaced.

NOTICE: If scuffed, nicked, burred or scoring conditions cannot be reconditioned by hand with a soft stone or crocus cloth, replace the component.

ASSEMBLE
1. Shift rail bushing (92) using J 39437.
2. Mainshaft bearing race (85) using J 8092 and J 39546.
3. Main bearing race snap ring (84).
4. Rear seal and boot (99) using J 39440.
- Locate drain hole in rear seal and boot (99) down.
5. O-ring seal to vehicle speed sensor (87).
6. Vehicle speed sensor (87) and clamp.
7. Vehicle speed sensor bolt (88).

Tighten
- Bolt (88) to 10 N.m (84 lb. in.).

CAUTION: The reverse lockout assembly is under spring pressure. Exercise caution when installing snap ring (173), as bodily injury may result.

8. Disassemble reverse lockout body assembly.
A. Reverse lockout plunger (170).
B. Reverse lockout outer spring (171).
C. Reverse lockout collar (172).
D. Compress reverse lockout plunger (170), collar (172) and outer spring (171) in vise and install snap ring (173).
E. Reverse lockout inner spring (174).
F. Install reverse lockout components in lockout body (175) and install snap ring (169).
G. Reverse lockout solenoid (89) to reverse lockout body assembly (91) using J 41099.

Tighten
- Solenoid (89) to 40 N.m (30 lb. ft.).

H. O-ring seal (160) to body assembly (91).
9. Reverse lockout assembly.
10. Reverse lockout assembly bolt (90).

Tighten
- Bolt (90) to 18 N.m (13 lb. ft.).

11. Transmission drain plug (101) with sealant GM P/N 12346004.

Tighten
- Transmission drain plug (101) to 18 N.m (13 lb. ft.).