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Home >> Saturn >> 2003 >> L200 Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transaxle >> Repair Instructions >> Input Shaft Assemble

Input Shaft Assemble

Tools Required

    Fig 1: View Of 3rd Gear Blocking Ring, 3rd Drive Gear & 3rd Gear Bearing Assembly
    GM895145Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate all rotating parts and bearings with manual transaxle lubricant P/N 21018899 during assembly.
  1. Install the 3rd gear bearing assembly, 3rd drive gear, and 3rd gear blocking ring.
    2. Fig 2: Installing 3rd/4th Gear Synchronizer Hub
    GM1227200Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Install the hub with the synchronizer hub washer groove facing up.
  2. Install the 3rd/4th gear synchronizer hub using the 87-91-204  and 87-92-202  . See Special Tools and Equipment . Align the gaps in the synchronizer hub with the blocking ring lugs.
    3. Fig 3: Measuring Clearance Between 2nd & 3rd Drive Gears
    GM895149Courtesy of GENERAL MOTORS CORP.
  3. Install the 3rd/4th gear synchronizer hub washer and retaining ring. The square edge on the retaining ring faces up, towards 4th gear.
  4. Measure the clearance between the 2nd and 3rd drive gears.

    Specification:  The tighten standard is 0.05-0.4 mm (0.002-0.015 in).

    5. Fig 4: View Of 3rd/4th Synchronizer Insert Pins & Springs
    GM895140Courtesy of GENERAL MOTORS CORP.
  5. Install the 3rd/4th gear synchronizer springs and pins.
    6. Fig 5: View Of 3rd/4th Gear Synchronizer Sleeve
    GM895152Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The tall teeth on the 3rd/4th synchronizer sleeve must align with the deep tooth gaps in the synchronizer hub.
  6. Install the 3rd/4th synchronizer sleeve onto the synchronizer hub.
    7. Fig 6: View Of Synchronizer Hub Detent
    GM895153Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not move the synchronizer sleeve after installing detent inserts. The inserts will not stay in position if the sleeve is moved. Only move the sleeve after installing the 4th drive gear.
  7. Move the 3rd/4th gear synchronizer sleeve down, towards 3rd gear, far enough to install the synchronizer detent inserts. Use a small screwdriver to depress the pins and springs, and install the detent inserts.
    8. Fig 7: View Of 4th Drive Gear, 4th Gear Blocking Ring & 4th Gear Bearing
    GM895137Courtesy of GENERAL MOTORS CORP.
  8. Install the 4th gear blocking ring to the synchronizer hub.
  9. Install the 4th gear bearing assembly and the 4th drive gear.
  10. Hold down the 4th gear and move the synchronizer sleeve up and down to check for proper operation.
    11. Fig 8: Pressing On Input Shaft Bearing
    GM1227202Courtesy of GENERAL MOTORS CORP.
  11. Press on the new input shaft bearing, next to the 4th drive gear, using the 78-41-067  . See Special Tools and Equipment . Support the shaft under the 2nd drive gear.
    12. Fig 9: Installing Bearing Retaining Ring
    GM895479Courtesy of GENERAL MOTORS CORP.
    NOTE: When installing a new bearing retaining ring, open the ring only as far as necessary to fit the ring over the shaft. Opening the ring too far will damage it.
  12. Install a new bearing retaining ring. Make sure the chamfered edge on the ring is facing up, away from the bearing.
    13. Fig 10: Measuring Clearance Between 4th Drive Gear & Input Shaft Bearing
    GM895156Courtesy of GENERAL MOTORS CORP.
  13. Measure the clearance between the 4th drive gear and input shaft bearing.

    Specification:  The tighten standard is 0.02-0.4 mm (0.002-0.015 in).

  14. Press on the new input shaft bearing, next to the 1st drive gear, using the sleeve from the 87-91-261  . See Special Tools and Equipment .
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