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Home › Saturn › 2004 › Ion Red Line › Repair and Diagnosis › Transmission › Manual Transaxle - Mu3 › Repair Instructions › 5th Gear and 5th Gear Synchronizer Assembly Replacement › Installation Procedure

Installation Procedure

    IMPORTANT: Lubricate the bearing assembly with manual transaxle lubricant P/N 21018899 during assembly.
  1. Install the 5th drive gear bearing assembly and the 5th drive gear.
  2. Install the blocking ring and blocking ring spring on the 5th gear.
    3. IMPORTANT: Gaps in the synchronizer hub must align with the blocking ring lugs.
  3. Carefully tap the synchronizer hub onto the input shaft using a mallet and large socket.
  4. Install a new 5th gear synchronizer hub snap ring.
    5. Fig 1: Installing 5th Gear Synchronizer Hub Snap Ring
    GM895505Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The 5th gear synchronizer sleeve can only be placed on the hub when tall teeth on the sleeve are aligned with deep teeth on the hub.
  5. Install the 5th gear fork and synchronizer sleeve together. Reference the sleeve alignment mark made during disassembly.
    6. Fig 2: Installing 5th Gear Synchronizer Sleeve
    GM895508Courtesy of GENERAL MOTORS CORP.
  6. Install a new 5th gear fork retaining pin.
  7. Install the rear cover. Refer to Rear Cover Replacement .
  8. Fill the transmission to proper level. Refer toTransmission Fluid Replacement .
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