GM Corvette 1984-1996 Repair Guide

Manual Transmission Assembly

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REMOVAL & INSTALLATION



1984-88 Vehicles

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. If equipped, disconnect the TV cable from the left TBI unit.
  6.  
  7. Remove the distributor cap, and position it aside.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. If equipped with a convertible, remove the upper and lower underbody braces.
  12.  

You will probably need an assistant to help you remove the exhaust system.

  1. Remove the complete exhaust system as an assembly, as follows:
    1. Disconnect the AIR pipe from the converter.
    2.  
    3. Unfasten the AIR pipe clamps from the exhaust manifold.
    4.  
    5. Detach the Oxygen sensor electrical connector.
    6.  
    7. Unfasten the bolts securing the mufflers to the hangers.
    8.  
    9. Remove the hanger bracket from the converter.
    10.  
    11. Detach the exhaust pipes from the exhaust manifolds, then carefully remove the exhaust system and place it in a safe place.
    12.  

  2.  
  3. Support the transmission assembly with a suitable jack.
  4.  
  5. Unfasten the bolts securing the driveline support beam to the axle and transmission. Remove the driveline beam from the vehicle.
  6.  
  7. Matchmark the position of the propeller shaft to the axle companion flange. Remove the trunnion bearing straps and disengage the rear universal joint from the axle. Slide the propeller shaft slip yoke out from the overdrive unit and remove the shaft from the vehicle.
  8.  
  9. Disconnect the cooler lines and the TV cable, if equipped, from the overdrive unit.
  10.  
  11. Detach the shift linkage from the side cover.
  12.  
  13. Detach the electrical connectors from the side cover switches, backup light switch, overdrive unit and speedometer sensor.
  14.  
  15. While supporting the engine with a suitable fixture, carefully lower the transmission.
  16.  
  17. Unfasten the bolts attaching the transmission to the bellhousing. Slide the transmission rearward to disengage the input shaft from the clutch. Remove the transmission from the vehicle.
  18.  
  19. Inspect the clutch components and replace components as necessary, as outlined later in this section.
  20.  

To install:


Click image to see an enlarged view

Fig. Fig. 1: View of the transmission components-1984 vehicle shown



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the transmission attachment-1987 vehicle shown

  1. Installation is the reverse of the removal procedure. Make sure to tighten all components securely and attach all connectors properly. Please note the following important steps:
    1. Clean and repack the clutch release bearing.
    2.  
    3. Tighten the transmission attaching bolts to 45-60 ft. lbs. (60-80 Nm) and the oil cooler line fittings to 8-12 ft. lbs. (11-16 Nm).
    4.  
    5. If equipped, adjust the TV cable, as outlined earlier in this section.
    6.  
    7. Install and align the driveline support beam installation as follows:

      To insure proper alignment of the driveline, you must maintain a clearance of 1.52-2.02 in. (39-51mm) between the top of the beam to the under body and a clearance of 0.85-1.35 in. (22-34mm) from the right (passenger) side of the beam to the side wall.
       
      Take the previous measurements directly above and to the right of the propeller shaft yoke.
       
      Refer to the driveshaft procedure, located later in this section, for additional installation information and tightening specifications.
       

    8.  

  2.  
  3. Refill the transmission with the proper type and amount of fluid as outlined in General Information & Maintenance of this repair guide.
  4.  

1989-92 Vehicles

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the center air outlet.
  4.  
  5. Remove the console and accessory trim plates.
  6.  
  7. Remove the control lever button.
  8.  
  9. Remove the shift lever knob assembly.
  10.  
  11. Remove the center console trim plate.
  12.  
  13. Remove the shift lever snapring.
  14.  
  15. Remove the shifter retainer nuts.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Remove the complete exhaust assembly.
  20.  
  21. Remove the driveshaft.
  22.  
  23. Support the transmission with a suitable jack.
  24.  
  25. Remove the driveline support beam.
  26.  
  27. Disengage the electrical connectors from the speed sensor, backup lamp switch and shift solenoid.
  28.  
  29. Remove the transmission to clutch housing attaching bolts.
  30.  
  31. Remove the transmission assembly from the vehicle.
  32.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the manual transmission-1992 vehicle shown

  1. Installation is the reverse of the removal procedure. Please note the following tightening specifications:

    Transmission-to-clutch housing bolts: 37 ft. lbs. (50 Nm), making sure to torque the bolts using the proper crisscross sequence, starting at the top right bolt.
     
    Driveline support beam-to-differential bolts: to 60 ft. lbs. (80 Nm).
     
    Driveline support beam-to-transmission bolts: to 37 ft. lbs. (50 Nm).
     

  2.  
  3. Check transmission oil level and add if necessary.
  4.  

In a horizontal position, the transmission should be filled to the point of overflow.

  1. Connect the negative battery cable.
  2.  

1993-96 Vehicles

See Figures 4 and 5

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the shifter button, retainer, shift knob, set screw and reverse inhibitor.
  4.  
  5. Remove the rear trim plate screws and the screw located underneath the cup holder mat.
  6.  
  7. Disengage the instrument panel harness connectors from the lighter and rear compartment lid release switch, then unclip the accessory plug harness.
  8.  
  9. Pry the locking tabs on the underside of the boot from the shaft groove, then remove the console trim plate and boot from the shaft.
  10.  
  11. Raise and support the vehicle safely.
  12.  
  13. Remove the complete exhaust assembly.
  14.  
  15. Remove the bolts retaining the driveline torque beam, then slide the beam outboard to gain access to the driveshaft.
  16.  
  17. Remove the parking brake cable clip, then remove the bolts retaining the support bracket.
  18.  
  19. To maintain drive train balance, matchmark the relationship between the driveshaft and the differential carrier yoke, then remove the bolts attaching the driveshaft to the yoke.
  20.  
  21. Slide the driveline torque beam rearward until it make contact with the rear exhaust hanger.
  22.  
  23. Support the transmission using an adjustable transmission jack.
  24.  
  25. Disengage the electrical connectors from the speed sensor, back-up lamp switch and the computer aided shift solenoid.
  26.  



Click image to see an enlarged view

Fig. Fig. 4: Location of the electrical connectors you need to unplug for transmission removal-1996 vehicle shown

  1. Remove the transmission to clutch housing attaching bolts.
  2.  
  3. Carefully lower the transmission and remove the transmission assembly from the vehicle.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the transmission attachment-1996 vehicle shown

To install:
  1. Install transmission assembly into the vehicle.
  2.  
  3. Install and tighten the transmission to clutch housing bolts to 37 ft. lbs. (50 Nm). Be sure to tighten the bolts using the proper crisscross sequence, starting at the top right bolt.
  4.  
  5. Engage the wiring harness connectors to the speed sensor, back-up lamp switch and shift solenoid.
  6.  
  7. Slide the driveline torque beam forward and onto the transmission extension housing.
  8.  
  9. Install the driveshaft, aligning the matchmarks made on the shaft and yoke during removal. Tighten the shaft-to-yoke retaining bolts to 18 ft. lbs. (24 Nm).
  10.  
  11. Install the bolts retaining the support bracket and tighten to 18 ft. lbs. (25 Nm).
  12.  
  13. Check transmission oil level and add if necessary.
  14.  

In a horizontal position, the transmission should be filled to the point of overflow.

  1. Install the parking brake cable clip.
  2.  
  3. Align the torque beam and install the retaining bolts. Tighten the beam-to-differential carrier bolt to 60 ft. lbs. (80 Nm) and the beam-to-transmission bolt to 37 ft. lbs. (50 Nm).
  4.  
  5. Install the complete exhaust system assembly.
  6.  
  7. Lower the vehicle.
  8.  
  9. Install the console trim plate and boot assembly.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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