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 MANUALSCHEVROLET1990CAVALIER BASE, 4D SEDAN, AUTOMATIC, 125C/MD9REPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONMANUAL TRANSOVERHAUL - MUNCIE 76 MM 5-SPEEDCOMPONENT DISASSEMBLY & REASSEMBLYOUTPUT SHAFTDISASSEMBLY
1990 Chevrolet Cavalier Base, 4D Sedan, Automatic, 125C/MD9
Output Shaft: Disassembly
1990 Chevrolet Cavalier Base, 4D Sedan, Automatic, 125C/MD9SECTION Disassembly
- Using Shaft Gear Remover/Installer (J-22912-01) and hydraulic press, remove reverse-5th gear synchronizer from output shaft. Remove 5th gear synchronizer ring, 5th gear and 5th gear bearing. See Figure . Before removing any synchronizer rings, ensure rings are labeled as to which gear they go with. DO NOT mix rings.
- Remove thrust washer and positioning ball from shaft. Remove snap ring. Using Shaft Gear Press Tube (J-36183) and press, remove 1st gear, 1st gear bearing, thrust bearing and thrust washer from shaft. See Figure .
- When 1st gear is pressed off output shaft, the following will be pressed off along with it: 2nd gear, 2nd gear bearing and race, 1st-2nd gear synchronizer, 1st and 2nd gear synchronizer rings and 3rd-4th gear. See Figure .
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.