GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 GTO 🢒 Transmission/Transaxle 🢒 Manual Transmission - Tremec 6-Speed 🢒 Transmission Disassemble

Transmission Disassemble CTSV

Extension Housing Removal

Tools Required

    • J 3289-20 Holding Fixture
    • J 39430 Transmission Holding Fixture

    Object Number: 1385053 Size: SH
  1. Remove the adapter plate bolts (1) and (2).

    2. Object Number: 1385057 Size: SH
  2. Install the J 39430  (2).
  3. Mount the transmission on a workbench using the J 3289-20  (1).
  4. Rotate the transmission into a horizontal position.
  5. Remove the transmission drain plug and drain the transmission fluid.
  6. Shift the transmission into neutral (N).

    7. Object Number: 1385061 Size: SH
  7. Remove the shifter cover plate bolts.
  8. Remove the shifter cover plate.

    9. Object Number: 1385063 Size: SH
  9. Remove the propshaft connector bolt.
  10. Remove the propshaft.

    11. Object Number: 1385059 Size: SH
  11. Remove the rear extension housing bolts and the rear extension housing.

Reverse Speed Gear Removal

    Object Number: 1385064 Size: SH
  1. Roll the shift guide rollpins.
  2. Remove the shift guide.
  3. Remove the shift shaft extension.

    4. Object Number: 38233 Size: SH
  4. Remove the rear bearing retainer ring.
  5. Remove the spacer.
  6. Remove the mainshaft rear roller bearing.
  7. Remove the spacer.

    8. Object Number: 38238 Size: SH
  8. Remove the retainer ring.
  9. Remove the reverse gear thrust washer.
  10. Remove the reverse gear.
  11. Remove the reverse gear caged needle bearing.
  12. Remove the wave washer.
  13. Remove the reverse gear synchronizer blocking ring.

Reverse Shift Fork Removal

    Object Number: 388430 Size: SH
  1. Remove the reverse synchronizer retainer ring.

    2. Object Number: 388431 Size: SH
  2. Remove and discard the reverse shift fork retainer ring.

    3. Object Number: 4810 Size: SH
  3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.

    4. Object Number: 388432 Size: SH
  4. Remove the following parts in order:
    5. 4.1. The thrust washer
    4.2. The reverse synchronizer assembly and the shift fork

5th/6th Speed Driven Gear Removal

Tools Required

    • J 8433 Universal Bridge Puller
    • J 39431 Gear Remover and Bolts

Object Number: 388433 Size: SH

Remove the 5th/6th speed driven gear. Use the J 8433 , the J 39431 and the J 39431-4.

Countershaft Extension Removal

    Object Number: 388434 Size: SH
  1. Remove the 5th/6th speed shift fork retainer ring.

    2. Object Number: 388437 Size: SH
  2. Rotate the transmission in the horizontal position with the guide plate up.
  3. Remove the countershaft extension assembly with the 5th/6th speed shift fork, 6th speed gear bearing spacer, 6th speed drive gear, and caged needle bearing. The 6th speed gear bearing spacer will slide out during removal of the countershaft extension assembly.

Transmission Case Removal

Tools Required

J 41099 Skip Shift Sensor Remover/ Installer


    Object Number: 1385065 Size: SH
  1. Remove the computer aided gear select solenoid.

    2. Object Number: 388460 Size: SH
  2. Remove the shift detent assembly.

    3. Object Number: 1385066 Size: SH
  3. Remove the shift detent plug, spring, and ball.

    4. Object Number: 1385067 Size: SH
  4. Remove 9 of the 11 adapter plate to transmission case bolts.
  5. Rotate the transmission into the vertical position.

    6. Object Number: 1385068 Size: SH
  6. Remove the last 2 adapter plate to transmission case bolts.
  7. Remove the shift lever guide bolts.

    8. Object Number: 1385069 Size: SH
  8. Remove the magnets from the transmission case.

    9. Object Number: 1385070 Size: SH
  9. Remove the transmission case and the offset lever together as follows:
    10. 9.1. Slide the transmission case up and off of the gear clusters and the shift shaft components.
    9.2. Hold the offset lever against the guide plate in order to prevent the release of the detent ball and the spring.
    9.3. Remove the offset lever from the transmission case.

Guide Plate Removal

    Object Number: 38317 Size: SH
  1. Remove the detent guide plate attaching bolts.
  2. Remove the detent guide plate.

Shift Shaft Assemblies and Gear Cluster Removal

    Object Number: 388439 Size: SH
  1. Rotate the 5th/6th and the reverse shift shaft levers off the shift interlock plate.
  2. Remove the 5th/6th and the reverse shift shaft assembly.

    3. Object Number: 388442 Size: SH
  3. Remove the countershaft. Lift up the mainshaft enough in order to remove the countershaft.

    4. Object Number: 388446 Size: SH
  4. Remove the mainshaft and the shift shaft components as an assembly.

    5. Important: When removing the shift shaft be careful not to lose the dowel pin.

  5. Remove the shift shaft assembly from the mainshaft.

    6. Object Number: 388448 Size: SH
  6. Remove the input shaft.

Transmission Disassemble Y Car

Extension Housing Removal

Tools Required

    • J 3289-20 Holding Fixture
    • J 44395 Transmission Holding Fixture

    Object Number: 639703 Size: SH
  1. Remove the adapter plate bolts (1) and (2).

    2. Object Number: 74206 Size: SH
  2. Install the J 44395 .
  3. Mount the transmission on a workbench using the J 3289-20 .
  4. Rotate the transmission into a horizontal position.
  5. Remove the transmission drain plug and drain the transmission fluid.
  6. Shift the transmission into neutral (N).

    7. Object Number: 74203 Size: SH
  7. Remove the rear extension housing bolts and the rear extension housing.

Reverse Speed Gear Removal

    Object Number: 38233 Size: SH
  1. Remove the rear bearing retainer ring.
  2. Remove the spacer.
  3. Remove the mainshaft rear roller bearing.
  4. Remove the spacer.

    5. Object Number: 38238 Size: SH
  5. Remove the retainer ring.
  6. Remove the reverse gear thrust washer.
  7. Remove the reverse gear.
  8. Remove the reverse gear caged needle bearing.
  9. Remove the wave washer.
  10. Remove the reverse gear synchronizer blocking ring.

Reverse Shift Fork Removal

    Object Number: 388430 Size: SH
  1. Remove the reverse synchronizer retainer ring.

    2. Object Number: 388431 Size: SH
  2. Remove and discard the reverse shift fork retainer ring.

    3. Object Number: 4810 Size: SH
  3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.

    4. Object Number: 388432 Size: SH
  4. Remove the following parts in order:
    5. 4.1. The thrust washer
    4.2. The reverse synchronizer assembly and the shift fork

5th/6th Speed Driven Gear Removal

Tools Required

    • J 8433 Universal Bridge Puller
    • J 39431 Gear Remover and Bolts

Object Number: 388433 Size: SH

Remove the 5th/6th speed driven gear. Use the J 8433 , the J 39431 and the J 39431-4.

Countershaft Extension Removal

    Object Number: 388434 Size: SH
  1. Remove the 5th/6th speed shift fork retainer ring.

    2. Object Number: 388437 Size: SH
  2. Rotate the transmission in the horizontal position with the guide plate up.
  3. Remove the countershaft extension assembly with the 5th/6th speed shift fork, 6th speed gear bearing spacer, 6th speed drive gear, and caged needle bearing. The 6th speed gear bearing spacer will slide out during removal of the countershaft extension assembly.

Transmission Case Removal

Tools Required

J 41099 Skip Shift Sensor Remover/ Installer


    Object Number: 350553 Size: SH
  1. Remove the computer aided gear select solenoid.

    2. Object Number: 71530 Size: SH
  2. Remove the reverse lockout solenoid from the reverse lockout body. Use the J 41099 .

    3. Object Number: 388457 Size: SH
  3. Remove the reverse lockout assembly bolt and the reverse lockout body.

    4. Object Number: 105689 Size: SH
  4. Remove the shifter cover plate retainer bolts.
  5. Remove the shifter cover plate.

    6. Object Number: 388460 Size: SH
  6. Remove the shift detent assembly.

    7. Object Number: 105692 Size: SH
  7. Remove 9 of the 11 adapter plate to transmission case bolts.
  8. Rotate the transmission into the vertical position.

    9. Object Number: 105690 Size: SH
  9. Remove the last 2 adapter plate to transmission case bolts.
  10. Remove the shift lever guide bolts.

    11. Object Number: 350556 Size: SH
  11. Remove the magnets from the transmission case.

    12. Object Number: 350558 Size: SH
  12. Remove the offset lever roll pin.

    13. Object Number: 388438 Size: SH
  13. Remove the transmission case and the offset lever together as follows:
    14. 13.1. Slide the transmission case up and off of the gear clusters and the shift shaft components.
    13.2. Hold the offset lever against the guide plate in order to prevent the release of the detent ball and the spring.
    13.3. Remove the offset lever from the transmission case.

Guide Plate Removal

    Object Number: 38317 Size: SH
  1. Remove the detent guide plate attaching bolts.
  2. Remove the detent guide plate.

Reverse Lockout Assembly Disassemble

    Object Number: 350562 Size: SH

    Caution: The reverse lockout assembly is under spring pressure. Exercise caution when removing the retainer ring, as bodily injury may result.

  1. Remove the O-ring (8) from the body (1).
  2. Remove the retainer ring (7) from the body (1).
  3. Remove the reverse lockout inner spring (2).
  4. Compress the reverse lockout plunger (6) and the collar (4) in a vise and remove the retainer ring (3).
  5. Remove the reverse lockout plunger (6).
  6. Remove the reverse lockout outer spring (5).
  7. Remove the reverse lockout collar (4).

Shift Shaft Assemblies and Gear Cluster Removal

    Object Number: 388439 Size: SH
  1. Rotate the 5th/6th and the reverse shift shaft levers off the shift interlock plate.
  2. Remove the 5th/6th and the reverse shift shaft assembly.

    3. Object Number: 388442 Size: SH
  3. Remove the countershaft. Lift up the mainshaft enough in order to remove the countershaft.

    4. Object Number: 388446 Size: SH
  4. Remove the mainshaft and the shift shaft components as an assembly.

    5. Important: When removing the shift shaft be careful not to lose the dowel pin.

  5. Remove the shift shaft assembly from the mainshaft.

    6. Object Number: 388448 Size: SH
  6. Remove the input shaft.

Transmission Disassemble GTO

Extension Housing Removal

Tools Required

    • J 3289-20 Holding Fixture Bench Mount
    • J 39430 Transmission Support Fixture
    • J 39431 Gear Remover and Bolts
    • J 8433 Universal Bridge Puller
    • J 41099 Solenoid Socket

    Object Number: 351939 Size: SH
  1. Remove the vent pipe.
  2. Install the J 39430 .
  3. Mount the transmission on a workbench using the J 3289-20 .
  4. Rotate the transmission into a horizontal position.
  5. Remove the transmission drain plug and drain the transmission fluid.
  6. Shift the transmission into neutral (N).

    7. Object Number: 1387177 Size: SH
  7. Remove the shifter boot.
  8. Remove the shift lever cover screws.
  9. Remove the shift lever cover.

    10. Object Number: 1387178 Size: SH
  10. Remove the shifter bolts.
  11. Remove the shifter and shifter gasket.

    12. Object Number: 38223 Size: SH
  12. Remove rear offset shift lever roll pin.

    13. Object Number: 38224 Size: SH
  13. Remove rear offset shift lever and isolator cup.

    14. Object Number: 408194 Size: SH
  14. Remove the reverse lockout solenoid from the reverse lockout body using J 41099 .

    15. Object Number: 408219 Size: SH
  15. Remove the reverse lockout assembly bolt and reverse lockout body.

    16. Object Number: 408217 Size: SH
  16. Remove the speed sensor bolt and the speed sensor.

    17. Object Number: 351941 Size: SH
  17. Remove the rear extension housing bolts and the rear extension housing.

    18. Object Number: 408222 Size: SH
  18. Remove the speed sensor reluctor wheel retaining ring.
  19. Remove the speed sensor reluctor wheel using J 39431 and J 8433 .
  20. Remove the speed sensor reluctor wheel retaining ring.

Reverse Speed Gear Removal

    Object Number: 38233 Size: SH
  1. Remove the rear bearing retainer ring.
  2. Remove the spacer.
  3. Remove the mainshaft rear roller bearing.
  4. Remove the spacer.

    5. Object Number: 38238 Size: SH
  5. Remove the retainer ring.
  6. Remove the reverse gear thrust washer.
  7. Remove the reverse gear.
  8. Remove the reverse gear caged needle bearing.
  9. Remove the wave washer.
  10. Remove the reverse gear synchronizer blocking ring.

Reverse Shift Fork Removal

    Object Number: 38239 Size: SH
  1. Remove the reverse synchronizer retainer ring.

    2. Object Number: 38241 Size: SH
  2. Remove the reverse shift fork retainer ring. Discard the retainer ring.

    3. Object Number: 4810 Size: SH
  3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.

    4. Object Number: 38242 Size: SH
  4. Remove the following parts in order:
    5. 4.1. The thrust washer
    4.2. The reverse synchronizer assembly and the shift fork

5th/6th Speed Driven Gear Removal

Tools Required

    • J 8433 Universal Bridge Puller
    • J 39431 Gear Remover

Object Number: 74207 Size: SH

Remove the 5th/6th speed driven gear, using the J 8433 and the J 39431 .

Countershaft Extension Removal

    Object Number: 38246 Size: SH
  1. Remove the 5th/6th speed shift fork retainer ring.

    2. Object Number: 1387176 Size: SH
  2. Rotate the transmission in the horizontal position with the guide plate up.
  3. Remove the countershaft extension assembly with the 5th/6th speed shift fork.

Transmission Case Removal

Tools Required

J 41099 Reverse Solenoid Socket


    Object Number: 33363 Size: SH
  1. Remove the computer aided gear select solenoid.

    2. Object Number: 38248 Size: SH
  2. Remove the shifter cover plate retainer bolts.
  3. Remove the shifter cover plate.

    4. Object Number: 388460 Size: SH
  4. Remove the shift detent assembly.

    5. Object Number: 105690 Size: SH
  5. Remove 9 of the 11 adapter plate to transmission case bolts.
  6. Rotate the transmission into the vertical position.
  7. Remove the last 2 adapter plate to transmission case bolts.
  8. Remove the shift lever guide bolts.

    9. Object Number: 38316 Size: SH
  9. Remove the magnets from the transmission case.

    10. Object Number: 38251 Size: SH
  10. Remove the offset lever roll pin.

    11. Object Number: 38607 Size: SH
  11. Remove the transmission case and the offset lever together as follows:
    12. 11.1. Slide the transmission case up and off of the gear clusters and the shift shaft components.
    11.2. Hold the offset lever against the guide plate in order to prevent the release of the detent ball and the spring.
    11.3. Remove the offset lever from the transmission case.

Guide Plate Removal

    Object Number: 38317 Size: SH
  1. Remove the detent guide plate attaching bolts.
  2. Remove the detent guide plate.

Reverse Lockout Assembly Disassemble

    Object Number: 408224 Size: SH

    Caution: The reverse lockout assembly is under spring pressure. Exercise caution when removing the retainer ring, as bodily injury may result.

  1. Disassemble the reverse lockout assembly in the following sequence:
  2. Remove the O-ring (8) from the body (1).
  3. Remove the retainer ring (7) from the body (1).
  4. Remove the reverse lockout inner spring (2).
  5. Compress the reverse lockout plunger (6) and the collar (4) in a vise and remove the retainer ring (3).
  6. Remove the reverse lockout plunger (6).
  7. Remove the reverse lockout outer spring (5).
  8. Remove the reverse lockout collar (4).

Shift Shaft Assemblies and Gear Cluster Removal

    Object Number: 38610 Size: SH
  1. Rotate the 5th/6th and the reverse shift shaft levers off the shift interlock plate.
  2. Remove the 5th/6th and the reverse shift shaft assembly.

    3. Object Number: 38611 Size: SH
  3. Remove the countershaft. Lift up the mainshaft enough in order to remove the countershaft.

    4. Object Number: 38612 Size: SH
  4. Remove the mainshaft and the shift shaft components as an assembly.
  5. Remove the shift shaft assembly from the mainshaft.

    6. Object Number: 105697 Size: SH
  6. Remove the 4th speed gear blocker ring.
  7. Remove the input shaft.