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Home › Saturn › 1996 › SW2 Standard › Repair and Diagnosis › Transmission › Manual Trans › Overhaul - SATURN 5-Speed › Component Disassembly & Reassembly › Output Shaft Assembly › Reassembly

Output Shaft Assembly: Reassembly

  1. Install 1st driven gear thrust bearing with Black side down. Install 1st driven gear bearing and gear. Install 1st synchronizer ring and spring.
  2. Press 1-2 synchronizer hub onto shaft, aligning tangs on synchronizer ring with slots in synchronizer hub. Install 1-2 synchronizer sleeve with gear side down. Ensure alignment marks on side of synchronizer assembly are aligned during synchronizer sleeve installation.
  3. Inspect synchronizer sleeve and check movement of 1st and 2nd gears. Install synchronizer spring on 2nd gear synchronizer ring and install unit on output shaft. Heat and install 2nd gear bearing race.
  4. Install 2nd gear bearing and 2nd driven gear. Install 3-4 driven gear with larger gear down. Press output shaft bearing on top of output shaft with snap ring groove up.
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