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 REPAIRSUBASSEMBLY SERVICEISUZU M-150 (77.5 MM) 4-SPEEDMAINSHAFT
1985 Chevrolet Astro Van M L4-151 2.5L
Mainshaft
1985 Chevrolet Astro Van M L4-151 2.5LSECTION Mainshaft
1. Using tool J-22912-01 or equivalent at rear face of second gear on mainshaft, remove mainshaft from center support using an arbor press, then remove 2nd gear, 1st/2nd synchronizer, 1st and 2nd blocker rings, 1st gear needle roller bearing, bearing collar, and thrust washer. Remove mainshaft rear bearing from center support.
2. Remove snap ring from front of mainshaft. Set blocks to rear face of 3rd gear and remove mainshaft using an arbor press, then remove 3rd gear, 3rd blocker ring, and 3rd/4th synchronizer.
3. install 3rd gear and 3rd gear blocker ring to front of mainshaft.
4. Install 3rd/4th synchronizer assembly to mainshaft using arbor press. Plates should be fitted against parts, so that force will be exerted on boss of synchronizer hub.
5. Install retaining ring to front of mainshaft, then install 2nd gear and 2nd blocker ring to rear of mainshaft.
6. install 1st/2nd synchronizer assembly to mainshaft using arbor press. Plates should be fitted against parts, so that force will be exerted on boss of synchronizer hub.
7. Install 1st gear bearing collar to mainshaft using tool J-8853-011 or equivalent, and an arbor press. install 1st blocker ring, needle roller bearing, and 1st gear, then install thrust washer with oil grooves turned toward gear.
8. Install reverse idler shaft into center support with suitable tool, after making certain spring pin is fitted to shaft.
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.