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HOMESERVICE MANUALSCHEVROLET1985CHEVY VAN G30, 5.7 M, 400/M40REPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONMANUAL TRANSOVERHAUL - NEW PROCESS A833 4-SPEED ODCOMPONENT DISASSEMBLY & REASSEMBLYMAINSHAFT & EXTENSION HOUSINGREASSEMBLY
1985 Chevrolet Chevy Van G30, 5.7 M, 400/M40

MAINSHAFT & Extension Housing: Reassembly

1985 Chevrolet Chevy Van G30, 5.7 M, 400/M40SECTION Reassembly
  1. If synchronizers are disassembled, make sure that parts are in good condition. To reassemble, place stop ring flat on bench followed by clutch gear and sleeve. Drop struts in slots and snap in strut spring, placing tang inside one strut.
  2. Turn assembly over on stop ring. Install second strut spring tang in different strut. Slide 2nd gear over mainshaft and against shoulder on shaft (synchronizer cone toward rear).
  3. Slide 1st-2nd synchronizer assembly (including stop ring with lugs indexed in hub slots) over mainshaft and down against 2nd gear cone. Secure with new snap ring.
    Fig 1: Exploded View of Synchronizer Assemblies
    G95G56057Courtesy of GENERAL MOTORS CORP.
  4. Slide next stop ring over shaft and index lugs into clutch hub slots. Slide 1st gear into position over mainshaft, against clutch sleeve gear. Install mainshaft bearing retaining ring and mainshaft rear bearing.
  5. Using arbor and driving tool, press bearing into position. Install new snap ring on shaft to secure bearing. Snap ring is selective fit for minimum end play.
  6. Install partially assembled mainshaft into extension housing far enough to engage bearing retaining ring in slot in housing. Compress ring with pliers so that mainshaft ball bearing can bottom against thrust shoulder in housing. Release ring and ensure that it is completely seated in groove in housing.
  7. Slide overdrive gear over mainshaft with synchronizer cone toward front. Install stop ring. Install 3rd-overdrive synchronizer assembly on mainshaft with shift fork slot toward rear and outside diameter of gear.
  8. Ensure that stop ring is indexed with shift struts. Install retaining ring. Grease front stop ring and install on synchronizer, indexing ring lugs with shift struts.
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

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  • • 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.