Component Disassembly & Reassembly: MAINSHAFT: Reassembly

1. Install 2nd gear needle bearing, 2nd gear and 2nd gear synchronizer ring. Press on low speed sleeve-hub assembly using Bearing Installer (Geo J37753 or Suzuki 09927-08210) and press on low gear bushing. Install low gear needle bearing, low gear synchronizer ring, low gear, steel ball and bearing washer.
2. Press on mainshaft center bearing using Bearing Installer (Geo J37753 or Suzuki 09925-18010) with Bearing Installer (Geo J35664). Install steel ball and bearing washer. Tap on reverse gear bushing using both bearing installers and a hammer. Install reverse gear needle bearing and reverse gear.
3. Tap on reverse sleeve-hub assembly using both bearing installers and a hammer. Install outer circlip, 5th gear synchronizer ring, 5th gear needle bearing, 5th gear, steel ball and 5th gear washer. Ensure oil slot on washer faces 5th gear.
4. Press on rear bearing using Rear Bearing Installer (Geo J28406 or Suzuki 09925-18010). Install rear bearing circlip, 3rd gear needle bearing, 3rd gear and high speed synchronizer ring. Tap on high speed sleeve-hub assembly using Needle Bearing Installer (Geo J35425 or Suzuki 09913-84510) and a hammer. Install 3rd gear circlip, input shaft needle bearing, high speed synchronizer ring and input shaft.

Fig 1: Measuring Synchronizer Ring Clearances

Courtesy of GENERAL MOTORS CORP.

Fig 2: Measuring Sleeve-To-Fork Clearance

Courtesy of GENERAL MOTORS CORP.