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 MANUALSCHEVROLET1995BLAZER 4D UTILITY, AWDREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONMANUAL TRANSMANUAL TRANSMISSION OVERHAUL - NEW VENTURE 1500 5-SPEEDTRANSMISSION DISASSEMBLY
1995 Chevrolet Blazer 4D Utility, AWD
Transmission Disassembly
1995 Chevrolet Blazer 4D Utility, AWDSECTION Transmission Disassembly
- Remove 2 bolts securing idler shaft support and collar to rear housing. Remove back-up light switch and vehicle speed sensor. Remove shift rail block-out bushing bolt, located on top of front housing near breather assembly.
- Using Detent Plug Remover (J-36509) and slide hammer, remove detent plug, spring and plunger from front housing. See Fig 1 . Remove output shaft oil seal. With transmission in vertical position, remove input shaft bearing retainer. Remove snap ring. Position transmission horizontally and remove 9 front housing-to-rear housing bolts. See Fig 2 .
- Remove countershaft roller bearing from countershaft or bearing shell. Remove roll pin from shift lever. DO NOT lose plunger and spring. Support shift rail end while driving out shift lever roll pin. Using 3/16" (5 mm) punch and air gun, remove shift rail socket roll pin. DO NOT apply excessive force, or pin will peen shift rail and damage rear housing shift rail bushing.
- Remove shift rail, shift rail socket, shift lever and shift rail block-out bushing. See Fig 2 . Rotate 3rd-4th shift fork counterclockwise and remove shift fork.
- Remove 5 bolts from center of rear housing securing output shaft bearing retainer. Remove rear housing from gear assemblies. Remove reverse idler gear and output shaft bearing retainer. Remove shift forks. Remove countershaft, countershaft bearing snap ring, and bearing. Press countershaft bearing off countershaft, if necessary. Remove output shaft assembly, input shaft and pilot bearing. See Figure .
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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.