M/T - Unit Repair Corrections

9216chevy03

Number: 91-201-7B

Section: 7B

Date: FEBRUARY 1991

Corporate Bulletin No.: 137202


Subject:
TRANSAXLE UNIT REPAIR CORRECTIONS


Model and Year:
1989-91 GEO METRO


Service Update


This bulletin amends the "Disassembling Transaxle" and "Assembling Transaxle" procedures found in MANUAL TRANSAXLE (Sec.7B) of the 1989, 1990 and 1991 Geo Metro Service Manuals (ST370-89, ST370-90 and ST370-91).

The special tool J 35309 or J 37975, shown in Figure 26 on page 7B-14 of the 1989, 1990 and 1991 Geo Metro Service Manuals, is not required to remove the countershaft nut. The manual transaxle disassembly and assembly procedures have been modified to incorporate a procedure to lock the transaxle into two gears, allowing for removal and installation of the countershaft nut.

Steps 5 and 6 of this bulletin replace steps 5 and 6 of the "Disassembling Transaxle" procedure found on pages 7B-13 and 7B-14. Steps 16 and 17 of this bulletin replace steps 16, 17 and 18 of the "Assembling Transaxle" procedure found on page 7B-31. Also, Figures 26 and 89 on pages 7B-14 and 7B-31, respectively, should be deleted.

DISASSEMBLING TRANSAXLE

Remove or Disconnect

5. Countershaft nut.

A. Engage transaxle into gear by pushing in on the gear shift shaft.
B. Engage fifth gear by sliding the fifth gear synchronizer sleeve down. The transaxle is now locked in two gears, preventing input shaft rotation and permitting countershaft nut removal.
C. Unstake countershaft nut.
D. Remove countershaft nut.

6. Remove the fifth gear shaft fork snap ring and remove the fifth gear shift fork, sleeve, hub, synchronizer ring, spring and keys as an assembly from input shaft (Figure 25).


ASSEMBLING TRANSAXLE

Install or Connect

16. Needle bearing to input shaft, apply oil and install fifth gear to input shaft.


17. Countershaft nut.

A. With the transaxle in fourth gear engage the fifth gear synchronizer. This will lock the transaxle in two gears, preventing countershaft rotation and allowing countershaft nut installation.

Tighten

Countershaft nut to 70 N-m (52 lbs.ft.).

B. Stake Countershaft nut with a drift punch and a hammer.
C. Disengage fifth gear synchronizer and shift the transaxle into neutral.