Component Disassembly & Reassembly: MAINSHAFT: Reassembly

1. Install low speed synchronizer springs, keys and sleeve onto low speed synchronizer hub. Install 2nd gear needle bearing, 2nd gear and low speed gear synchronizer ring onto mainshaft. Press on low speed sleeve-hub assembly and 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. Install reverse synchronizer springs and keys to synchronizer hub (thick side of keys and sleeve should face toward 5th gear). Install reverse synchronizer sleeve to reverse synchronizer hub. Install steel ball and bearing washer onto mainshaft. Tap on reverse gear bushing using bearing installers and a hammer. Install reverse gear needle bearing and reverse gear.
3. Tap on reverse sleeve-hub assembly using bearing installers and a hammer. Install high speed and reverse hub circlip, high speed 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. Install rear bearing circlip and speedometer drive gear. Install high speed synchronizer springs, keys and sleeve onto high speed synchronizer hub. Install 3rd gear needle bearing, 3rd gear and high speed sleeve-hub assembly onto mainshaft. Install high speed and reverse hub circlip.

Fig 1: Measuring Synchronizer Ring Clearances

Courtesy of GENERAL MOTORS CORP.

Fig 2: Measuring Sleeve-To-Fork Clearance

Courtesy of GENERAL MOTORS CORP.