N-1,1-2 HARD SHIFT 1-2,2-3 GEAR CLASH

VEHICLES AFFECTED: 1983-84 'J' Series Equipped With Five Speed Transaxle

Some comments of difficult shifting into 1st and 2nd and gear clash when upshifting into 2nd and 3rd on 1983-84 'J' series equipped with five speed manual transmissions have been received. This may be caused by input shaft bearing preload. If the clash does not occur with a fast shift, or disappears when the transmission warms up, the condition is very likely caused by input shaft bearing preload.

These conditions can be corrected by reducing the input shaft shim thickness. In December of 1932, production began using a reduced shim. These transaxles are identified by a green dab on the rear cover.

These conditions can usually be corrected without removing the transaxle from the vehicle, in the following manner:

1. Raise vehicle on a frame hoist - leave transmission in gear.

2. Remove the left front wheel.

3. Remove inner fender plastic splash shield.

4. Remove transmission rear cover aand gasket shown on Page 13 of Shop Manual, Section 76mm Manual Transaxle. It may be necessary to bend the sheet metal slightly.

5. Remove shifter fork pin.

6. Remove nut from end of output shaft - impact wrench works best.

7. Remove synchronizer and fork together with needle rollers.

8. Remove nut on and of input shaft.

9. Remove gear and rear plate. Bearing and shim pack will be exposed.

10. Remove input shaft shim. Replace with a shim that is the minimum thickness without causing axial movement of the input shaft.

11. On reassembly, apply Loctite or equivalent to input and output shaft nuts. Also stake bearing retainer to transaxle case screws (P/N 94248159).

There should be no input shaft axial movement after rear plate is replaced. Procedure may be repeated, if necessary, as long as the input shaft does not become loose. Below is list of shim part numbers and their thickness:

M200 INPUT SHAFT SHIMS

P/N Thickness ---- --------- 94115571 1.00 mm 94115572 1.08 mm 94115573 1.16 mm 94115574 1.24 mm* 94115575 1.32 mm* 94115576 1.40 mm* 94115577 1.48 mm* 94115578 1.56 mm* 94115579 1.64 mm* 94115580 1.72 mm 94115581 1.80 mm 94115582 1.88 mm 94115583 1.96 mm 94115584 2.04 mm 94115585 2.12 mm 94115586 2.20 mm 94115587 2.28 mm 94115588 2.36 mm 94115589 2.44 mm

*Most commonly used shims.

Use most applicable Labour Operation from Canadian Labour Time Guide and Claim.

Labour Time: 1.1 hrs.

NOTE: Item #47 is the input shaft bearing shim. The service manual incorrectly identifies it as the output shaft bearing shim.

NOTICE: Item no. 47 is the input shaft bearing shim. The service manual incorrectly identifies it as the output shaft bearing shim.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.