GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Avalanche - 2WD 🢒 Transmission/Transaxle 🢒 Manual Transmission - MK5 🢒 Transmission Assemble

Tools Required

    • J 35799-A Fifth Gear Installer
    • J 22912-01 Split Plate Bearing Puller
    • J 35451 Reverse Light Switch Socket

    Object Number: 164129 Size: SH
  1. Apply GM P/N 1052271 lightly as you assemble each part.
  2. Install the following parts onto the input shaft:
    3. • The third gear
    • The needle roller bearing
    • The synchronizer ring
    • The number 2 hub sleeve assembly
  3. Place the synchronizer ring on the gear. Align the clutch hub grooves with the projection on the synchronizer ring.

    4. Object Number: 164136 Size: SH
  4. Choose a selective snap ring that will allow minimum axial play. Refer to Transmission Specifications .

    5. Object Number: 164137 Size: SH
  5. Place the fourth gear synchronizer ring on the gear and align the clutch hub grooves with the projections on the synchronizer ring.
  6. Use a J 22912-01 and a press to install the fourth gear and the radial ball bearing.

    7. Object Number: 164139 Size: SH
  7. Install the selective snap ring.

    8. Object Number: 164140 Size: SH
  8. If you are servicing any hub sleeve assembly, refer to the following procedure:
    9. 8.1. Position the key springs so that the end gaps are not lined up.
    8.2. Install the clutch hub and the shifting keys to the hub sleeve.
    8.3. Install the shifting key springs under the shifting keys.

    Object Number: 164150 Size: SH
  9. Install the first gear locking ball in the shaft.
  10. Install the thrust washer securely over the locking ball.
  11. Install the synchronizer ring on the gear and align the clutch hub grooves with the projections on the synchronizer ring.
  12. Install the first gear and the number 1 hub sleeve.

    13. Object Number: 164152 Size: SH
  13. Choose a selective snap ring that will allow the minimum axial play. Refer to Transmission Specifications .

    14. Object Number: 164156 Size: SH
  14. Install the following parts:
    15. • The spacer
    • The synchronizer ring
    • The second gear
    • The needle bearing
  15. Install the third driven gear.

    16. Object Number: 164166 Size: SH
  16. Install the output gear spacer.
  17. Install the fourth driven gear and the bearing.
  18. Install the magnet.
  19. Install the oil receiver with two bolts. Finger tighten the bolts.
  20. Install the differential into the transaxle case.
  21. Inspect and adjust the side bearing preload. Refer to Differential Replacement .

    22. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  22. Install the transaxle case.

    23. Tighten

        • Tighten the transaxle case bolts to 29 N·m (22 lb ft).
        • Tighten the oil receiver bolt to 11 N·m (97 lb in).

    Object Number: 164171 Size: SH
  23. Install the following components together:
    24. • The input shaft
    • The output shaft
  24. Install the following components:
    25. • The shift shafts
    • The shift fork
  25. Place the number 1 shift forks into the groove of the number 1 hub sleeve.
  26. Place the number 2 shift forks into the groove of the number 2 hub sleeve.
  27. Insert the number 1 fork shaft into the number 1 shift fork hole.

    28. Object Number: 164176 Size: SH
  28. Insert two interlock balls into the reverse shift fork.
  29. Install the following components:
    30. • The number 3 shift fork shaft
    • The reverse shift fork.

    Object Number: 164181 Size: SH
  30. Install the following components:
    31. • The number 2 shift fork shaft
    • The shift head
  31. Insert the 3 lock bolts.

    32. Tighten
    Tighten the lock bolts to 16 N·m (12 lb ft).

  32. Install the three shift fork shaft snap rings.

    33. Object Number: 164182 Size: SH
  33. Install the reverse shift arm.

    34. Tighten
    Tighten the reverse shift arm bolts to 17 N·m (13 lb ft).

  34. Install the reverse idle gear and shaft. Align the shaft to the idler gear mark.

    35. Object Number: 164183 Size: SH

    Important: Before you install the transaxle case, verify that no sealing material is on the case. Do not drop oil on the contacting surfaces.

  35. Apply GM P/N 1052756 Sealant.
  36. As soon as the sealant is applied, install the transaxle case.
  37. Insert 16 transaxle case bolts.

    38. Tighten
    Tighten the case bolts to 29 N·m (22 lb ft).


    Object Number: 164184 Size: SH
  38. Install the lock ball assemblies into the case.
  39. Apply GM P/N 1052624 sealant to the lock ball assembly plug threads.

    40. Object Number: 164188 Size: SH
  40. Install the plugs.

    41. Tighten
    Tighten the plugs to 39 N·m (29 lb ft).

  41. Apply GM P/N 1052756 sealant to the reverse idler gear shaft lock bolt.
  42. Install the reverse idler gear shaft lock bolt.

    43. Tighten
    Tighten the bolt to 29 N·m (22 lb ft).


    Object Number: 164190 Size: SH
  43. Install the output shaft bearing snap rings.
  44. Install the snap ring number 2 fork shaft.
  45. Install the rear bearing retainer.

    46. Tighten
    Tighten the rear bearing retainer bolts to 27 N·m (20 lb ft).


    Object Number: 164192 Size: SH
  46. Use a J 35799-A to install the fifth gear.
  47. Install the following components:
    48. • The spacer
    • The needle roller bearing
    • The fifth gear and synchronizer ring
  48. Support the tip of the input shaft with a spacer in order to raise the transaxle assembly.
  49. Install the following components:
    50. • The number 3 hub sleeve assembly
    • The shift fork
  50. Align the synchronizer ring slots with the shifting keys.
  51. Install the hub sleeve assembly.

    52. Object Number: 164196 Size: SH
  52. Choose a selective snap ring that allows the minimum axial play. Refer to Transmission Specifications .
  53. Engage the gears.
  54. Install the locknut.

    55. Tighten
    Tighten the locknut to 118 N·m (87 lb ft).

  55. Disengage the gears.
  56. Stake the locknut.
  57. Install the number 3 fork shaft lock bolt.

    58. Tighten
    Tighten the number 3 fork shaft lock bolt to 16 N·m (12 lb ft).

  58. Install the shift and select lever assembly.
  59. Apply GM P/N 1052624 to the bolts. Insert the bolts into the shift and select lever assembly.

    60. Tighten
    Tighten the shift and select lever assembly bolts to 20 N·m (14 lb ft).

  60. Install the lock bolt.

    61. Tighten
    Tighten the lock bolt to 29 N·m (22 lb ft).

  61. Apply GM P/N 1052756 in an even 1 mm (0.04 in) bead on the case cover.
  62. Install the transaxle case cover.

    63. Tighten
    Tighten the case cover bolts to 18 N·m (13 lb ft).

  63. Install the front bearing retainer.

    64. Tighten
    Tighten the front bearing retainer bolts to 11 N·m (97 lb in).

  64. Install the backup switch using a J 35451 .

    65. Tighten
    Tighten the backup switch to 40 N·m (30 lb ft).

  65. Install the VSS into the transaxle case. Secure the VSS with one retaining bolt.

    66. Tighten
    Tighten the VSS retaining bolt to 11 N·m (97 lb in).

  66. Release the fork and bearing.