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 SHAFTREASSEMBLY
1990 Chevrolet Cavalier Base, 4D Sedan, Automatic, 125C/MD9
Output Shaft: Reassembly
1990 Chevrolet Cavalier Base, 4D Sedan, Automatic, 125C/MD9SECTION Reassembly
- Prior to assembly, lubricate all components, and heat 2nd gear bearing race to 250°F (120°C) for 7-10 minutes. Heat 3rd-4th gear to 250°F (120°C) for a minimum of 20 minutes.
- Install thrust washer with chamfered side facing down. See Fig 1 . Install thrust bearing with needles facing down. Install 1st gear bearing. Install 1st gear with cone facing up. Install 1st gear synchronizer ring.
- Using Shaft Gear Press Tube (J-36183) and Shaft Gear Press Tube Reducer (J-36184), install 1st-2nd gear synchronizer with small outside diameter groove on sleeve facing 1st gear. See Fig 1 .
- Start hydraulic press operation to press on 1st-2nd gear synchronizer, but stop before tangs engage. DO NOT allow tangs to engage. Lift and rotate 1st gear and 1st gear synchronizer to engage synchronizer ring tangs. Continue to press until synchronizer is properly seated. Ensure all metal shavings are removed.
- Install 2nd gear bearing race, bearing and 2nd gear with cone facing down. Using shaft gear press tube and shaft gear press tube reducer, install 3rd-4th gear with large outside diameter facing down. Install NEW snap ring. Install thrust washer with positioning ball and slotted thrust washer. Retain ball with lubricant. See Fig 1 .
- Align inside diameter slot of thrust washer with positioning ball. Install 5th gear bearing and 5th gear with cone facing up. Install 5th gear synchronizer ring. Using shaft gear press tube and shaft gear press tube reducer, press reverse gear and 5th gear synchronizer onto output shaft.
- Start hydraulic press operation to press on reverse-5th gear synchronizer, but stop before the tangs engage. DO NOT allow tangs to engage. Lift and rotate 5th gear and 5th gear synchronizer ring until tangs engage. Ensure thrust washer stays down. Continue to press together until synchronizer is properly seated. Ensure all metal shavings are removed.
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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.