2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.

52SS Page 1

Manual Transmission/Transaxle: Service and Repair

1. Transmission Disassemble

Transmission Disassemble (Y Car MM6 and MZ6)

Extension Housing Removal

^ Tools Required
- J 3289-20 Holding Fixture
- J 44395 Transmission Holding Fixture

1. Remove the auxiliary cooler pump bolt (2).

2. Remove the auxiliary cooler pump (1) (MZ6 only).

3. Remove the adapter plate bolts (1) and (2).

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 2

4. Install the J 44395.

5. Mount the transmission on a workbench using the J 3289-20.
6. Rotate the transmission into a horizontal position.
7. Remove the transmission drain plug and drain the transmission fluid.
8. Shift the transmission into neutral (N).

9. Remove the rear extension housing bolts and the rear extension housing.

Reverse Speed Gear Removal

1. Remove the rear bearing retainer ring.

2. Remove the spacer.
3. Remove the mainshaft rear roller bearing.
4. Remove the spacer.
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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

1. Remove the reverse synchronizer retainer ring.

2. Remove and discard the reverse shift fork retainer ring.

3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.
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4. Remove the following parts in order:

1. The thrust washer
2. The reverse synchronizer assembly and the shift fork

5th/6th Speed Driven Gear Removal

^ Tools Required
- J 8433 Universal Bridge Puller
- J 39431-1 Gear Remover and Bolts

Remove the 5th/6th speed driven gear. Use the J 8433, the J 39431-1 and the J 39431-4.

Countershaft Extension Removal

1. Remove the 5th/6th speed shift fork retainer ring.

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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

1. Remove the computer aided gear select solenoid.

2. Remove the reverse lockout solenoid from the reverse lockout body. Use the J 41099.

3. Remove the reverse lockout assembly bolt and the reverse lockout body.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 6

4. Remove the shifter cover plate retainer bolts.

5. Remove the shifter cover plate.

6. Remove the shift detent assembly.

7. Remove 9 of the 11 adapter plate to transmission case bolts.

8. Rotate the transmission into the vertical position.

9. Remove the last 2 adapter plate to transmission case bolts.

10. Remove the shift lever guide bolts.
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11. Remove the magnets from the transmission case.

12. Remove the offset lever roll pin.

13. Remove the transmission case and the offset lever together as follows:
1. Slide the transmission case up and off of the gear clusters and the shift shaft components.
2. Hold the offset lever against the guide plate in order to prevent the release of the detent ball and the spring.
3. Remove the offset lever from the transmission case.

Guide Plate Removal

1. Remove the detent guide plate attaching bolts.

2. Remove the detent guide plate.

Reverse Lockout Assembly Disassemble

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 8

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

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

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. Remove the countershaft. Lift up the mainshaft enough in order to remove the countershaft.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 9

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.

Remove the shift shaft assembly from the mainshaft.

6. Remove the input shaft.

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

2. Mainshaft and Input Shaft Disassemble

Mainshaft and Input Shaft Disassemble

Mainshaft

^ Tools Required
- J 36513 Split Plate
- J 39442 Press Adapter
- J 39443 Split Plate
- J 39473 Mainshaft Bearing Installer

1. Important:
Measure the 4th speed gear synchronizer wear gap before disassembling the mainshaft.

Install the input shaft in the adapter plate.

2. Install the mainshaft on the input shaft.
3. Using a feeler gauge measure the gap between the 4th speed gear blocking ring and the 4th speed gear.
4. Replace the 4th speed gear friction cone and blocking ring when the gap is less than 1.27 mm (0.050 inch).

5. Notice:
Do not overtighten the J 36513 split plate past the gear teeth or damage to gear may occur.

Using the J 36513, close the split plate only enough to support the gear teeth, and the J 39442, remove the following parts in order:
1. If an O-ring is present on the mainshaft, remove and discard the O-ring. The O-ring was used for manufacturing purposes only.
2. The mainshaft large tapered bearing
3. The 1st speed gear
4. The 1st speed gear caged needle bearing
5. The 1st speed bearing spacer

6. Remove the following parts in order:

1. The 1st speed gear inner cone
2. The 1st speed gear friction cone
3. The 1st speed gear blocking ring
4. The retainer ring
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7. Important:
The synchronizer hubs and sliding sleeves are a selected assembly. Keep these parts together as originally assembled.

Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.

8. Remove the 2nd speed gear. The 1st/2nd speed synchronizer assembly, the 2nd speed gear blocking ring, the 2nd speed gear friction
cone, and the 2nd speed gear inner cone will press off with the 2nd speed gear. Use the J 36513 in an inverted position, J 39442 and
a hydraulic press.

9. Remove the 2nd speed gear spacer and caged needle bearing.

10. Remove the mainshaft small tapered bearing. Use the J 39442, the J 39443, and a hydraulic press.
11. Discard the small tapered bearing.
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12. Remove the following parts in order:

1. Retainer
2. 4th gear thrust washer
3. 4th gear inner cone
4. 4th gear friction cone
5. 4th gear blocking ring

13. Important:
The synchronizer hubs and sliding sleeves are a selected assembly. Keep these parts together as originally assembled.

Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.

14. Use the J 39473, V-blocks, and a hydraulic press to remove the 3rd speed gear. The 3rd/4th speed synchronizer assembly, the 3rd
speed gear blocking ring, the 3rd speed gear friction cone, the 3rd speed gear inner cone, thrust washer, and spacer will press off
with the 3rd speed gear.
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15. Remove the 3rd speed gear caged needle bearing.

Input Shaft

^ Tools Required
- J 22912-O1 Split Plate
- J 23907 Slide Hammer
- J 39594 Bearing Race Remover

1. Important:
Do not replace the tapered bearing or the bearing race unless inspection shows that the bearing or the race are damaged.

Remove the tapered bearing from the input shaft, using the J 22912-01 and a hydraulic press.

2. Remove the bearing race from the input shaft, using the J 23907 and the J 39594.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

3. Countershaft Disassemble

Countershaft Disassemble

^ Tools Required
- J 22912-O1 Split Plate
- J 39473 Mainshaft Bearing Installer
- J 39511 Split Plate
- J 39547 Press Adapter

Important:Do not replace tapered bearings unless inspection shows bearing damage.

1. Remove the small tapered bearing, using the J 22912-O1 with the J 39473 and a hydraulic press.
2. Discard the small tapered bearing.

3. Remove the large tapered bearing, using the J 39511, the J 39547, and a hydraulic press.
4. Discard the large tapered bearing.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

4. Countershaft Extension Disassemble

Countershaft Extension Disassemble

^ Tools Required
- J 22910-01Split Plate
- J 39442 Press Adapter
- J 39443 Split Plate

1. Remove the 5th/6th speed shift fork.

2. Remove the following parts in order:

1. The 6th speed drive gear
2. The 6th speed gear bearing spacer
3. The caged needle bearing
4. The 6th speed gear bearing spacer

3. Remove the following parts in order:

1. The 5th/6th speed synchronizer retainer ring
2. The thrust washer
3. The 6th speed drive gear inner cone
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4. The 6th speed drive gear friction cone

5. The 6th speed drive gear blocking ring
4. Discard the retainer ring.

5. Remove the 5th speed drive gear, using the J 22910-01 and a hydraulic press. The 5th/6th speed synchronizer assembly, and the 5th
speed drive gear blocking ring, friction cone, inner cone and thrust washer will press off with the 5th speed drive gear.
6. Remove the 5th speed drive gear caged needle bearing.

7. Important:
Do not replace the small tapered bearing unless inspection shows bearing damage.

Remove the small tapered bearing, using the J 39442, the J 39443, and a hydraulic press.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

5. Synchronizers Disassemble

Synchronizers Disassemble

1st/2nd, 3rd/4th, 5th/6th Synchronizers

Important:
Synchronizer components are not interchangeable. Keep all the synchronizer components separate. The synchronizer hubs and the
sliding sleeves are a selected assembly. Keep the hubs and the sliding sleeves together as originally assembled.

1. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.

2. Remove the synchronizer springs. Use a small-blade screwdriver.

3. Remove the synchronizer sleeve and the keys from the hub.

Reverse Synchronizer
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1. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.

2. Remove the synchronizer spring. Use a small-bladed screwdriver.

3. Remove the synchronizer sleeve from the hub. Press against the inner hub.
4. Turn the hub over. The keys will slide out from the hub.

5. Remove the following parts using a small-blade screwdriver:

1. The synchronizer key retainer
2. The synchronizer spring
6. Discard the synchronizer key retainer.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

6. Synchronizers Cleaning and Inspection

Synchronizers Cleaning and Inspection

1. Clean all the synchronizer parts in a suitable solvent. Air dry all the synchronizer parts.
2. Inspect the synchronizer parts for the following conditions:
^ Burrs
^ Cracks
^ Chamfer for excessive wear
^ Free movement of the clutching sleeves on their hubs
^ Worn or damaged clutch teeth
^ Distorted springs
3. Replace synchronizer parts that are worn or damaged. Replace a burred or nicked part that cannot be reconditioned by hand. Use a
soft stone or a crocus cloth.

4. Measure the gap between the vertical faces of the blocking ring teeth and the speed gear as follows:
1. Assemble the correct blocking ring with the correct speed gear.
2. The blocking ring must be fully seated on the gear.
3. Use a feeler gauge to measure the forward gear gap.
4. Use a feeler gauge to measure the reverse gear gap. Measure the gap without the wave washer in between the blocking ring and
the reverse gear. The nominal gap is 1.27 - 2.16 mm (0.050 - 0.085 inch) for the 1st and 2nd gear. The nominal gap is 1.27 - 2.03
mm (0.050 - 0.080 inch) for the 3rd, 4th, 5th and 6th gear. Replace the friction cones and blocker rings when the gap is
significantly less than specified.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

7. Synchronizers Assemble

Synchronizers Assemble

1st/2nd Synchronizer

1. Check the synchronizer assembly scribe marks for correct positions.

2. Install the synchronizer sleeve to the hub (align the key openings in the hub with the cuts in the synchronizer sleeve).
3. Install the keys with the slots facing the hub.

4. Assemble the first spring (assemble the spring tangs to the side of two keys).
5. Assemble the second spring (assemble the spring tangs to the side of two keys such that the gap is not between the same two keys as
the first spring).

3rd/4th, 5th/6th Synchronizers

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 2

1. Check the synchronizer assembly scribe marks for correct positions.

2. Install the synchronizer sleeve to the hub (align the key openings in the hub with the cuts in the synchronizer sleeve).
3. Install the keys with the slots facing the hub.

4. Assemble the first spring (assemble the spring tang to one of the key slots).
5. Assemble the second spring (assemble the spring tang on the same key but in the opposite direction).

Reverse Synchronizer

1. Check the synchronizer assembly scribe marks for correct positions.

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2. Install the synchronizer sleeve to the hub (align the key openings in the hub with the cuts in the synchronizer sleeve).
3. Install the keys with the slots facing the hub.

4. Assemble the first spring (assemble the spring tang to one of the key slots).
5. Assemble the second spring (assemble the spring tang on the same key but in the opposite direction).

6. Install a new synchronizer key retainer with the key retainer tangs over the synchronizer keys.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

8. Shift Rail and Fork Assemblies Disassemble

Shift Rail and Fork Assemblies Disassemble

1st/2nd, 3rd/4th Shift Rail Assembly

1. Remove the neutral return cam pin (3) from the shift shaft (2).

2. Remove the 1st/2nd shift fork (1) from the shift shaft (2).

3. Remove the shift link (2) from the 1st/2nd shift fork (1).

4. Remove the 3rd/4th shift fork (2) from the shift shaft (1).
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5. Remove the shift link (1) from the 3rd/4th shift fork (2).

6. Remove the interlocking plate (2) from the selector pin (1).

7. Remove the selector roll pin (5).

8. Remove the selector pin (3) from the shift shaft (1).

5th/6th, Reverse Shift Rail Assembly

^ Tools Required
- J 23907 Slide Hammer
- J 39439-2 Bushing Remover

1. Remove the reverse collar roll pin (1).

2. Remove the reverse collar (2).
3. Remove the reverse shift lever roll pin (3).
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4. Remove the reverse shift lever (2) from the shift shaft (1).

5. Remove the 5th/6th shift lever (2) from the shift rail (1).

6. Remove the snap ring (1) from the 5th/6th shift lever (2).

7. Important:
Do not replace the bushings unless inspection shows bushing damage.

Remove the 5th/6th shift shaft lever bushings (1) and (3) from the 5th/6th shift lever (2) using the J 23907 and the J 39439-2.
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Manual Transmission/Transaxle: Service and Repair

9. Shift Rail and Fork Assemblies Cleaning and Inspection

Shift Rail and Fork Assemblies Cleaning and Inspection (Y Car MM6 and MZ6)

1. Clean the shift shaft and fork assembly parts with a suitable solvent. Air dry all the parts.

2. Inspect the shift forks and the shift links for excessive wear, fractures or distortion.

3. Inspect the shift shaft lever bushings for excessive wear.

4. Inspect the shift fork nylon inserts for wear.

5. Replace parts that are fractured, excessively worn, or distorted.
6. Replace an excessively worn or burred shift shaft.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

10. Shift Rail and Fork Assemblies Assemble

Shift Rail and Fork Assemblies Assemble

1st/2nd, 3rd/4th Shift Rail Assembly

^ Tools Required
- J 36850 Transjel Lubricant

1. Install the selector pin (3) on the shift shaft (4).

2. Align the roll pin hole on the selector pin (4) with the roll pin hole on the shift shaft (2).
3. Install the roll pin (5) through the selector pin (3) and the shift shaft (1).

4. Install the interlocking plate (2) on the selector pin (1).

5. Install the shift link (1) in the 3rd/4th shift fork (2).

6. Install the 3rd/4th shift fork (2) on the shift shaft (1).
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7. Align the notch on the shift link (2) with the selector roll pin (1).

8. Install the shift link (2) with the 1st/2nd shift fork (1).

9. Install the 1st/2nd shift fork (1) on the shift shaft (2).

10. Install the 1st/2nd shift shaft link (1) on top of the 3rd/4th shift shaft link (3) on the interlocking plate and the selector roll pin
assembly (2).

11. Important:
The neutral return cam pin fits loosely in the shift shaft. Use the J 36850 to hold the neutral return cam pin in place.

Install the neutral return cam pin (3) in the neutral return can pin hole (1) on the shift shaft (2).

5th/6th, Reverse Shift Rail Assembly

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^ Tools Required
- J 39437 Bushing Installer

1. Install the 5th/6th shift shaft lever bushings (1) and (3) in the 5th/6th shift lever (2) using the J 39437 and a hammer.

2. Install the retainer ring (1) on the 5th/6th shift lever (2).

3. Install the 5th/6th shift lever (2) on the shift shaft (1).

4. Install the reverse shift lever (2) on the shift shaft (1).
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5. Install the reverse lever roll pin (3).

6. Install the reverse collar (2).
7. Install the reverse collar roll pin (1).
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

11. Transfer Case and Adapter Plate Disassemble
Transfer Case and Adapter Plate Disassemble (Y Car MM6 and MZ6)

Transmission Case

^ Tools Required
- J 8092 Universal Driver Handle
- J 23907 Slide Hammer
- J 39439-2 Bushing Remover
- J 39790 Mainshaft Bearing Race Remover
- J 39791 Countershaft Bearing Race Remover

1. Remove the transmission case fill plug (1) (MM6 only).

2. Remove the coolant temperature switch (2) (MZ6 only).

3. Remove the reverse lamp switch (MM6 only).

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4. Remove the E-Z key switch (1) (MZ6 only).

5. Remove the dowel pins.

6. Important:
Do not replace the bearing race unless inspection shows bearing race damage.

Remove the countershaft bearing race, using the J 8092 and the J 39791.

7. Important:
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Do not replace the bearing race unless inspection shows bearing race damage.

Remove the mainshaft bearing race, using the J 8092 and the J 39790.

8. Remove the 1st/2nd and the 3rd/4th shift shaft bushings, using the J 23907 and the J 39439-2.

Adapter Plate

^ Tools Required
- J 23907 Slide Hammer
- J 39439-2 Bushing Remover

1. Remove the input shaft bearing race and the shim.

2. Remove the countershaft bearing race and the shim.

3. Remove the adapter plate plug (MM6 only).

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4. Remove the input shaft seal.

5. Important:
Do not replace the bushing unless inspection shows bushing damage.

Remove the 1st/2nd and the 3rd/4th shift shaft bushing, using the J 23907 with the J 39439-2.

6. Remove the 1st/2nd and the 3rd/4th shift shaft seals (1) and (2).

7. Remove the dowel pins.

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

12. Transfer Case and Adapter Plate Cleaning and Inspection
Transfer Case and Adapter Plate Cleaning and Inspection (Y Car MM6 and MZ6)

Transmission Case

1. Clean the transmission case in a suitable solvent. Air dry the transmission case.
2. Clean all sealant material from retainer bolt threads.
3. Inspect the transmission case for the following conditions:
^ Cracks
^ Scratches
^ Damaged threads
^ Burrs
^ Nicked mounting surfaces
^ Damaged sealing surfaces
^ Damaged front or rear bearing bores
4. Inspect the machined mating surfaces for flatness with a straight edge.
5. Inspect the bearing races and bores for wear, scratches or grooves.
6. Inspect the bushing for excessive wear.
7. Use a fine mill file to dress minor scratches or burrs.
8. If scratches, or grooves or scoring cannot be removed by hand with a soft stone or crocus cloth, replace the component.
9. Clean up damaged threads with the correct size tap.
10. Replace a cracked housing.
11. Replace worn bushings.

Adapter Plate

1. Clean the adapter plate parts with a suitable solvent. Air dry all the parts.
2. Inspect the adapter plate parts for the following conditions:
^ Cracks - Replace the adapter plate parts if cracks are found.
^ Scratches
^ Burrs
^ Nicked mounting surfaces
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^ Damaged sealing surfaces

^ Damaged front or rear bearing bores
3. Inspect the machined mating surfaces for flatness. Check the mating surfaces with a straight edge.
4. Inspect the bearing races and bores for wear, scratches or grooves.
5. Inspect the bushing for excessive wear. Replace worn bushings.
6. Use a fine mill file to dress minor scratches or burrs.
7. If scratches, or grooves or scoring cannot be removed by hand with a soft stone or crocus cloth, replace the component.
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Manual Transmission/Transaxle: Service and Repair

13. Transfer Case and Adapter Plate Assemble
Transfer Case and Adapter Plate Assemble (Y Car MM6 and MZ6)

Transmission Case

^ Tools Required
- J 8092 Universal Driver Handle
- J 36190 Universal Driver Handle
- J 39435 Bearing Race Installer
- J 39439-4 Bushing Installer
- J 39439-3 Bushing Installer

1. Install the 1st/2nd and the 3rd/4th shift shaft bushings. Use the J 36190, the J 39439-4, and the J 39439-3.

2. Install the mainshaft bearing race, using the J 8092 and the J 39435.

3. Install the countershaft bearing race, using the J 8092 and the J 39435.
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4. Install the dowel pins.

5. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the reverse lamp switch.

6. Notice:
Refer to Fastener Notice in Service Precautions.

Install the reverse lamp switch.

Tighten the switch to 27 Nm (20 ft. lbs.).
7. Install the coolant temperature sensor (MZ6 only).
Tighten the sensor to 39 Nm (29 ft. lbs.).
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8. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the transmission case fill plug, MM6
only.

9. Install the transmission case fill plug (1), MM6 only.

Tighten the transmission case fill plug to 18 Nm (13 ft. lbs.).

10. Notice:
The H-pattern on the guide plate must face the extension housing. If the guide plate is installed incorrectly, then damage will occur.

Install the guide plate and the guide plate bolts.

Tighten the bolts to 22 Nm (16 ft. lbs.).

Adapter Plate

^ Tools Required
- J 39433 Input Shaft Seal Installer
- J 39439-1 Shift Rail Bushing Remover/Installer
- J 42464 Shift Shaft Seal Installer
- J 42496 Inner Shift Rail Inner Seal Installer
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1. Install the dowel pins.

2. Notice:
If the 1st/2nd, 3rd/4th speed shift shaft bushing is installed incorrectly it will interfere with the inner shift rail seal causing a leak.

Install the 1st/2nd, 3rd/4th speed shift shaft bushing flush with adapter plate, using the J 39439-1.

3. Install the inner shift rail seal (1) using the J 42496. Garter spring should face inside of transmission.
4. Install the outer shift rail seal (2) using the J 42464.

5. Install the input shaft seal, using the J 39433.

6. Install the countershaft bearing shim and bearing race. Refer to Input Shaft, Mainshaft and Countershaft in Shimming Procedures (Y
Car MM6 and MZ6) Shimming Procedures (CTS, GTO, SSR M10).
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7. Install the input shaft bearing shim and bearing race. Refer to Input Shaft, Mainshaft and Countershaft in Shimming Procedures (Y
Car MM6 and MZ6) Shimming Procedures (CTS, GTO, SSR M10).
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Manual Transmission/Transaxle: Service and Repair

14. Extension Housing Disassemble

Extension Housing Disassemble

^ Tools Required
- J 26941 Bearing Race Remover
- J 23907 Slide Hammer

1. Remove the reverse idler shaft bracket bolts.

2. Remove the reverse idler gear, the roller bearing, and the reverse idler shaft.

3. Remove the countershaft extension bearing race, the shim, and the funnel.
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4. Remove the output shaft seal (some models). Pry out the seal with a suitable tool.

5. Remove the mainshaft bearing race retainer ring.

6. Important:
Do not replace the bearing race unless inspection shows bearing race damage.

Remove the mainshaft bearing race using J 26941 and J 23907.

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

15. Extension Housing Cleaning and Inspection

Extension Housing Cleaning and Inspection

1. Clean the rear extension housing in a suitable solvent. Air dry the housing.
2. Inspect the extension housing for the following:
^ Cracks
^ Scratches
^ Damaged threads
^ Burrs
^ Nicked mounting surfaces
^ Damaged sealing surfaces
^ Damaged front or rear bearing bores
3. Replace a cracked housing.
4. Clean up damaged threads with the correct size thread tap.
5. Inspect the machined mating surfaces for flatness (Check the mating surfaces with a straight edge).
6. Use a fine mill file to dress minor scratches or burrs.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

16. Extension Housing Assemble

Extension Housing Assemble

^ Tools Required
- J 8092 Drive Handle
- J 21426 Outer Output Shaft Seal Installer
- J 39546 Bearing Race Installer
- J 39437 Bushing Installer

1. Install the mainshaft bearing race, using the J 39546 and the J 8092.

2. Install the mainshaft bearing race retainer ring.

3. Install the output shaft seal using the J 21426 (some models).
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 2

4. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the transmission case drain plug.

5. Notice:
Refer to Fastener Notice in Service Precautions.

Install the transmission case drain plug.

Tighten the plug to 18 Nm (13 ft. lbs.).
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

17. Bearings and Spacers Cleaning and Inspection
Bearings and Spacers Cleaning and Inspection

1. Notice:
Do not allow the bearings to spin. Turn them slowly by hand. Spinning the bearings may damage the race and the rollers.

Clean all the bearing parts in a suitable solvent. Air dry all the parts.
2. Lubricate the bearings. Use Dexron® III transmission lubricant.
3. Inspect the bearings and journals for roughness and unusual wear or damage.
4. Inspect the mainshaft bearing journals for wear.
5. Inspect the mainshaft speed gear bearings for wear.
6. Inspect the main drive gear pilot bearing rollers for wear.
7. Replace parts which show signs of excessive wear.
8. Do not file surfaces which have been hardened and precision ground.
9. Replace worn or damaged bearings.
10. Replace mated bearing parts when only one part is damaged.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

18. Gears Cleaning and Inspection

Gears Cleaning and Inspection

1. Clean all the parts in a suitable solvent. Air dry all the parts.
2. Inspect the gear tooth surfaces on all the gear sets for the following conditions:
^ Cracks
^ Pitting
^ Nicks
^ Chipped gear teeth
^ High spots (Small-shiny spots on the gear teeth mating surface) that could cause gear noise
3. Inspect for damaged splines on the input shaft, mainshaft, and the countershaft extension.
4. Remove nicks and burrs with a soft stone or a crocus cloth.
5. Replace a burred or nicked part that cannot be reconditioned by hand.
6. Replace gears and gear assemblies that are worn or damaged.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

19. Countershaft Extension Assemble

Countershaft Extension Assemble

^ Tools Required
- J 5590 Press Tube
- J 39473Mainshaft Bearing Installer

1. Install a new small tapered bearing, using the J 39473, V-blocks, and a hydraulic press.

2. Do the following when installing the 5th/6th speed synchronizer assembly:

1. Start the press operation.
2. Stop pressing before the keys engage the blocking ring slots.
3. Lift and rotate the 5th speed gear in order to engage the keys with the blocking ring.
4. Continue pressing until the synchronizer is seated.
3. Install the following parts in order:
1. The 5th speed drive gear caged needle bearing
2. The 5th speed drive gear
3. The thrust washer
4. The 5th speed drive gear inner cone
5. The 5th speed drive gear friction cone
6. The 5th speed drive gear blocking ring
7. The 5th/6th speed synchronizer assembly (The inside diameter (ID) groove on the sleeve faces 5th speed gear.) Use the J 5590
and a hydraulic press.

4. Install the following parts in order:

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 2

1. The 6th speed drive gear blocking ring

2. The 6th speed drive gear friction cone
3. The 6th speed drive gear inner cone
4. The thrust washer
5. A new 5th/6th speed synchronizer retainer ring

5. Install the following parts in order:

1. The 6th speed drive gear spacer
2. The 6th speed drive gear caged needle bearing
3. The 6th speed drive gear spacer
4. The 6th speed drive gear

6. Install the 5th/6th speed shift fork.

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

20. Countershaft Assemble (Main Shaft)

Countershaft Assemble (Main Shaft)

^ Tools Required
- J 39438 Bearing Installer
- J 5590 Press Tube

1. Install a new large tapered bearing, using the J 39438, U-blocks and a hydraulic press.

2. Install a new small tapered bearing, using the J 5590 and a hydraulic press.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

21. Mainshaft and Input Shaft Assemble

Mainshaft and Input Shaft Assemble

Mainshaft

^ Tools Required
- J 36183 Press Tube
- J 36184 Press Tube Adapter
- J 39371 1st/2nd Synchronizer Installer
- J 39473 Mainshaft Bearing Installer

1. Install the 3rd speed gear caged needle bearing and the spacer.

2. Check the 3rd/4th speed gear synchronizer assembly scribe marks for correct positions.

3. Install the 3rd/4th synchronizer assembly as follows:

1. Start the press operation.
2. STOP pressing before the keys engage the blocking ring slots.
3. Lift and rotate the 3rd speed gear in order to engage the keys with the blocking ring.
4. Continue pressing until the synchronizer is seated.
4. Install the following parts in order, using the J 36183, the J 36184, and a hydraulic press:
1. The 3rd speed gear
2. The spacer
3. The thrust washer
4. The 3rd speed gear inner cone
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 2

5. The 3rd speed gear friction cone

6. The 3rd speed gear blocking ring
7. The 3rd/4th speed gear synchronizer assembly (the groove on the sleeve faces the 3rd speed gear).

5. Install in the following order:

1. 4th gear blocking ring
2. 4th gear friction cone
3. 4th gear inner cone
4. 4th gear thrust washer
5. 3rd/4th synchronizer retainer ring

6. Install a new mainshaft small tapered bearing, using the J 39473, V-blocks, and a hydraulic press.

7. Install the 2nd speed gear caged needle bearing and bearing spacer.

8. Do the following when installing the 1st/2nd synchronizer assembly:

1. Start the press operation.
2. Stop pressing before the keys engage the blocking ring slots.
3. Lift and rotate the 2nd speed gear in order to engage the keys with the blocking ring.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 3

4. Continue pressing until the synchronizer is seated.

9. Install the following parts in order using the J 39371 and a hydraulic press:
1. The 2nd speed gear
2. The 2nd speed gear inner cone
3. The 2nd speed gear friction cone
4. The 2nd speed gear blocking ring
5. The 1st/2nd synchronizer assembly (The ID groove on the sleeve faces the 1st speed gear.)

10. Install the following parts in order:

1. The retainer ring
2. The blocking ring
3. The friction cone
4. The inner cone

11. Install the following parts in order:

1. The 1st speed gear bearing spacer
2. The 1st speed gear caged needle bearing
3. The 1st speed gear
4. The mainshaft large tapered bearing and the O-ring seal

Input Shaft

^ Tools Required
- J 28537-17Bearing Race Installer
- J 25234Press Tube

1. Install a new bearing race on the input shaft, using the J 28537-17 and a hydraulic press.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 4

2. Install a new tapered bearing on the input shaft. Use the J 25234 and a hydraulic press.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

22. Transmission Assemble

Transmission Assemble (Y Car MM6 and MZ6)

Shift Shaft Assemblies and Gear Clusters Installation

^ Tools Required
- J 36850 Transjel Lubricant Assembly Lube

1. Lubricate all components as assembly progresses, using J 36850.

2. Install the input shaft in the adapter plate.

3. Assemble the shift shaft to the mainshaft.

4. Install the neutral return roll pin to the shift shaft.
5. Install the mainshaft and the shift shaft assembly into the adapter plate.

6. Install the countershaft assembly using the following sequence:

1. Lift up the mainshaft assembly enough in order to install the countershaft assembly.
2. Install the countershaft assembly.
3. Lift the mainshaft assembly enough in order to rotate the input shaft to engage the synchronizer keys with 4th gear blocking ring.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 2

7. Install the 5th/6th and the reverse shift shaft. Align the slots of the shift shaft levers with the interlock plate.

Reverse Lockout Assembly Assemble

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

Install the reverse lockout plunger (6).

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

Transmission Case Installation

^ Tools Required
- J 41099 Skip Shift Sensor Remover/Installer
- J 36850 Transjel Lubricant

1. Important:
Lubricate all components as the assembly progresses. Use J 36850 or the equivalent.

Apply sealant GM P/N United States 12345739, GM P/N Canada 10953472 or equivalent to the transmission case to adapter plate
mating surface.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 3

2. Install the ball detent and the spring in the front offset lever.

3. Do the following in order to install the transmission case and the offset lever:
1. Shift the transmission into NEUTRAL in order to keep the 3rd/4th shift shaft from engaging.
2. Install the offset lever.
3. Compress the front offset lever together while sliding it onto the shift shaft. This will prevent the spring release of the inner
components.
4. Slide the transmission case onto the gear clusters and the shift rail components.

4. Apply threadlock GM P/N United States 12346004, GM P/N Canada 10953480 or equivalent to the threads of the shift lever guide
bolts.

5. Notice:
Refer to Fastener Notice in Service Precautions.

Install the shift lever guide bolts and pull up on 5th/6th and reverse shift rail assembly. This will help align the slot of the shift
interlock plate with the guide bolt hole.
Tighten the bolts to 27 Nm (20 ft. lbs.).
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 4

6. Install the adapter plate to transmission case bolts.

Tighten the bolts to 48 Nm (36 ft. lbs.).

7. Install the magnets into the transmission case.

8. Install the offset lever roll pin.

9. Install the shift detent assembly.

Tighten the detent assembly to 40 Nm (30 ft. lbs.).

10. Apply sealant GM P/N United States 12345739, GM P/N Canada 10953472 or the equivalent to the mating surface of the cover
plate.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 5

11. Install the transmission case cover and the case cover bolts.
Tighten the bolts to 20 Nm (15 ft. lbs.).

12. Install the reverse lockout body and bolt in the cover plate.
Tighten the bolts to 18 Nm (13 ft. lbs.).

13. Install the reverse lockout solenoid to reverse lockout body assembly, using the J 41099.
Tighten the solenoid to 40 Nm (30 ft. lbs.).
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 6

14. Install the computer aided gear select solenoid.

Tighten the solenoid to 40 Nm (30 ft. lbs.).

Countershaft Extension Installation

1. Position the transmission in the horizontal position.

2. Install the countershaft extension assembly and the 5th/6th shift fork. The splines of the countershaft extension must engage the
splines of the countershaft.

3. Install the 5th/6th shift fork retainer ring.

5th/6th Speed Driven Gear Installation

^ Tools Required
- J 39441 5th/6th Driven Gear Installer
- J 39441-10 5th Gear Installer Adapter

Install the 5th/6th speed driven gear using the J 39441 and J 39441-10. The smaller outside diameter (OD) of the gear faces down.

Reverse Shift Fork Installation

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 7

1. Install the reverse shift fork, the synchronizer and the thrust washer.

2. Install a new shift fork retainer ring.

3. Install the reverse synchronizer retainer ring.

Reverse Speed Gear Installation

1. Install the following parts in order:

1. The blocking ring
2. The wave washer
3. The wave washer so the concave side faces the blocking ring
4. The caged needle bearing
5. The reverse speed gear
6. The thrust washer
7. The retainer ring
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 8

2. Install the following parts in order:

1. The spacer
2. The roller bearing
3. The spacer
4. The roller bearing retainer ring

Extension Housing Assemble

^ Tools Required
- J 44395 Transmission Holding Fixture

1. Install the following parts in order:

1. The funnel
2. The selective shims. Refer to the Countershaft Extension in Shimming Procedures (Y Car MM6 and MZ6) Shimming Procedures
(CTS, GTO, SSR M10).
3. The countershaft extension bearing race

2. Install the following parts in order:

1. The reverse idler shaft
2. The roller bearing
3. The reverse idler gear
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 9

3. Apply GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the reverse idler shaft brackets bolt threads.

4. Notice:
Refer to Fastener Notice in Service Precautions.

Install the following parts in order:

1. The reverse idler shaft bracket
2. The reverse idler shaft bracket bolts
Tighten the bolts to 25 Nm (18 ft. lbs.).

5. Apply sealant GM P/N 12345739 (Canadian P/N 10953472) or equivalent to the extension housing to the transmission case mating
surface.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 10

6. Apply thread sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the top 2 extension housing bolts.

7. Important:
Align the 5th/6th shift shaft to the extension housing bore in order to install the extension housing.

Install the extension housing.

8. Install the extension housing bolts.
Tighten the bolts to 48 Nm (36 ft. lbs.).
9. Install the vent tube.

10. Remove the J 44395.

2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 11

11. Install the remaining 2 adapter plate bolts (1) and (2).
Tighten the adapter plate bolts to 48 Nm (36 ft. lbs.).

12. Install the auxiliary coolant pump (1) (MZ6 only).

13. Install the auxiliary coolant pump bolt (2) (MZ6 only).
Tighten the bolt to 19 Nm (14 ft. lbs.).
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 1

Manual Transmission/Transaxle: Service and Repair

23. Shimming Procedures

Shimming Procedures (Y Car MM6 and MZ6)

Input Shaft, Mainshaft, and Countershaft

^ Tools Required
- J 8001 Dial Indicator Set
- J 39444-1 Countershaft End Play Rod
1. Rotate the transmission adapter plate to the vertical position.

2. Install the following assemblies in order:

1. The input shaft to the adapter plate
2. Align the 4th speed gear blocking ring to the input shaft.
3. The mainshaft assembly
4. The countershaft (lift up the mainshaft enough to install the countershaft)

3. Install the transmission case.

4. Notice:
Refer to Fastener Notice in Service Precautions.

Install the adapter plate to transmission case bolts.

Tighten the bolts to 35 Nm (26 ft. lbs.).
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 2

5. Measure the input shaft/mainshaft end play using the following procedure:
1. Place the tip of the J 8001 -3 on the end of the mainshaft.
2. Move the input shaft up and down.
3. Record the measurement.
6. Select a shim to achieve 0.00 - 0.05 mm (0.000 - 0.002 inch) preload.
7. Remove the J 8001 -3.

8. Remove the adapter plate plug (MM6 only).

9. Remove the auxiliary coolant pump bolt (2) (MZ6 only).
10. Remove the auxiliary coolant pump (1) (MZ6 only).

11. Place the tip of the J 8001 -3 on the end of the countershaft.
12. Measure the countershaft end play using the following procedure:
1. Install the J 39444-1 through the adapter plate plug hole. Screw the J 39444-1 into the countershaft.
2. Move the countershaft up and down with the countershaft end play rod J 39444-1.
3. Record the measurement.
13. Select a shim to achieve 0.00 - 0.05 mm (0.000 - 0.002 inch) preload.
14. Remove the J 8001 -3.
15. Remove the J 39444-1.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 3

16. Remove the shift lever guide bolts.

17. Remove the adapter plate to the transmission case bolts.

18. Remove the transmission case.

19. Remove the following parts in order:

1. The countershaft (lift up the mainshaft enough to remove the countershaft).
2. The mainshaft assembly
3. The input shaft from the adapter plate
4. The input shaft bearing race
5. The countershaft bearing race

Countershaft Extension

^ Tools Required
- J 8001 Dial Indicator Set
- J 39444-2 Countershaft Extension End Play Rod
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 4

1. Important:
The following procedure cannot be performed accurately until the countershaft shimming procedure has been completed and the
transmission has been assembled to the point of installing the countershaft extension.

Rotate the transmission in the horizontal position.

2. Install the countershaft extension to the countershaft. Make sure the splines fully engage.

3. Notice:
Refer to Fastener Notice in Service Precautions.

Install the extension housing and the extension housing retainer bolts.
Tighten the bolts to 35 Nm (26 ft. lbs.).

4. Remove the adapter plate plug (MM6 only).

5. Remove the auxiliary coolant pump bolt (2) (MZ6 only).
6. Remove the auxiliary coolant pump (1) (MZ6 only).
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 5

7. Install the J 39444-2 through the adapter plate plug hole.

8. Screw J 39444-2 into the countershaft extension.

9. Measure the countershaft extension end play using the following procedure:
1. Install a J 8001 so the tip is on the end of the countershaft extension end play rod.
2. Rotate the transmission in the vertical position.
3. Move the countershaft extension up and down using the J 39444-2.
4. Record the measurement.
10. Select a shim to achieve 0.05 - 0.13 mm (0.002 - 0.005 inch) axial play.
11. Remove the J 8001.
12. Remove the J 39444-2.

13. Apply sealant GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the plug threads.
2006 Chevrolet Corvette V8-6.0L VIN U Copyright © 2013, ALLDATA 10.52SS Page 6

14. Install the adapter plate plug (MM6 only).

Tighten the plug to 27 Nm (20 ft. lbs.).
15. Install the auxiliary coolant pump (1) (MZ6 only).
16. Install the auxiliary coolant pump bolt (2) (MZ6 only).
Tighten the bolt to 19 Nm (14 ft. lbs.).

17. Install the countershaft extension.

18. Install the countershaft extension bearing race.

19. Install the extension housing bolts and the extension housing.