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Countershaft Assembly: Reassembly

  1. Using Bearing Installer (Geo J-34846, Suzuki 09923-78210) and a hammer, drive on RH bearing. Install 1st and 2nd gear needle bearing, apply oil and install 1st gear and 1st gear synchronizer ring. Ensure proper synchronizer ring is used. See Figure.
    NOTE: Key slot width of 1st gear synchronizer ring is smaller than that of the 2nd gear synchronizer ring.
  2. Support countershaft in bearing installer and press on low speed sleeve and hub assembly. Ensure synchronizer key slots are aligned with keys. Check for free rotation of 1st gear.
  3. Install snap ring. Ensure snap ring is installed securely in groove. Install needle bearing, apply oil and install 2nd gear synchronizer ring and 2nd gear.
  4. Support countershaft in bearing installer. Press on 3rd gear and spacer. Press on 4th gear. With countershaft still supported in bearing installer, install LH bearing.
Fig 1: Exploded View Of Input Shaft, Countershaft & Reverse Shaft Assemblies
G93D24854Courtesy of GENERAL MOTORS CORP.
Fig 2: Checking Gear & Synchronizer Ring
G93E24855Courtesy of GENERAL MOTORS CORP.
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