Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET1985ASTRO VAN M L4-151 2.5LREPAIR AND DIAGNOSISTRANSMISSION AND DRIVETRAINMANUAL TRANSMISSION/TRANSAXLESERVICE AND REPAIRASSEMBLESAGINAW (76 MM) 4 SPEED
1985 Chevrolet Astro Van M L4-151 2.5L
Saginaw (76 mm) 4 Speed
1985 Chevrolet Astro Van M L4-151 2.5LSECTION Saginaw (76 mm) 4 Speed
1. Load a row of roller bearings and a thrust washer at each end of the countergear. Use heavy grease to hold them in place.
2. Install countergear through case rear opening with a tanged thrust washer at each end and install countershaft and woodruff key from rear of case. Be sure countershaft picks up both thrust washers and that the tangs are aligned with their notches in the case.
3. Install reverse idler gear, shaft and woodruff key from rear of case.
4. Expand extension housing snap ring and assemble extension housing over mainshaft.
5. Load roller bearings into clutch gear bore, using heavy grease to hold them in place, place blocker ring on gear cone with teeth toward gear, and install gear and ring onto mainshaft. Do not install clutch gear bearing at this time. Be sure notches in blocker ring align with synchronizer keys.
6. Using new gasket, install mainshaft and extension assembly through rear opening in case. Use sealing cement on bottom bolt.
7. Install large outer snap ring on clutch gear bearing and install bearing onto gear stem snap ring and bearing retainer.
NOTE: With transmission in neutral, install cover assembly. Be sure the shift forks are properly aligned in their grooves in the synchronizer sleeves before attempting to tighten cover bolts.
2. Install countergear through case rear opening with a tanged thrust washer at each end and install countershaft and woodruff key from rear of case. Be sure countershaft picks up both thrust washers and that the tangs are aligned with their notches in the case.
3. Install reverse idler gear, shaft and woodruff key from rear of case.
4. Expand extension housing snap ring and assemble extension housing over mainshaft.
5. Load roller bearings into clutch gear bore, using heavy grease to hold them in place, place blocker ring on gear cone with teeth toward gear, and install gear and ring onto mainshaft. Do not install clutch gear bearing at this time. Be sure notches in blocker ring align with synchronizer keys.
6. Using new gasket, install mainshaft and extension assembly through rear opening in case. Use sealing cement on bottom bolt.
7. Install large outer snap ring on clutch gear bearing and install bearing onto gear stem snap ring and bearing retainer.
NOTE: With transmission in neutral, install cover assembly. Be sure the shift forks are properly aligned in their grooves in the synchronizer sleeves before attempting to tighten cover bolts.
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.