Counter Gear Shaft Assemble

Tools Required

• DT 46493  (DW09913-80112) Gear, Bearing Installer. See Special Tools .
• DT 46495  (DW09925-98221) Gear, Bearing Installer. See Special Tools .
• DT 46496  (DW09940-53111) Gear, Bearing Installer. See Special Tools .
• KM-466-A  Gear, Bearing Remover/Installer. See Special Tools .

Fig 1: 1st Gear, Bearing & Synchronizer Ring
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Coat the inner parts of the gear, the bearing and the oil seal with gear fluid.
1. Install the 1st gear bearing (2).
2. Install the 1st gear (3).
3. Install the 1st gear synchronizer ring (1).
Fig 2: 1st-2nd Synchronizer Springs & Hub
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Be careful there is the difference of key groove width between the 1st synchronizer ring and the 2nd synchronizer ring.
4. Install the 1st-2nd synchronizer springs to hub.

   Specifications:

   • The key groove width for the 1st synchronizer rings-A (1) is 8.2 mm (0.323 in).
   • The key groove width for the 2nd synchronizer ring-B (2) is 9.6 mm (0.378).
Fig 3: 1st-2nd Synchronizer Keys, Hub & Sleeve
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Ensure A=B when installing the keys.
5. Install the 1st-2nd synchronizer keys to hub.
6. Install the hub (2) to the sleeve (1).
Fig 4: Inserting 1st-2nd Synchronizer Hub Assembly Into Counter Shaft Using A Hammer, DT 46496 & KM-466-A
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Position the synchronizer key to the 1st gear synchronizer ring groove.
7. Insert the 1st-2nd synchronizer hub assembly into the counter shaft usingDT 46496  (1), KM-466-A  (2), and a hammer. See Special Tools .
Fig 5: 1st-2nd Gear Synchronizer Circlip, Ring & Bearing
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Position the 2nd synchronizer ring groove to the synchronizer hub key.
8. Install the 2nd synchronizer ring.
9. Install the 1st-2nd gear synchronizer circlip.
Fig 6: 2nd Gear & Bearing
Courtesy of GENERAL MOTORS CORP.
10. Install the 2nd gear bearing (2).
11. Install the 2nd gear (1).
Fig 7: Installing 3rd Gear Spacer Using A Hammer & DT 46493
Courtesy of GENERAL MOTORS CORP.
12. Insert the 3rd gear and the 3rd-4th gear spacer into the counter shaft.
13. Install the 3rd-4th gear spacer (2) using DT 46493  and a hammer. See Special Tools .
14. Install the 3rd gear spacer (3) using the gear, bearing installerDT 46493  and a hammer. See Special Tools .
Fig 8: Installing 4th Gear Spacer Using A Hammer & DT 46495
Courtesy of GENERAL MOTORS CORP.
15. Install the 4th gear (2) to the counter shaft using DT 46495  and a hammer (1). See Special Tools .
Fig 9: Installing Left Side Bearing To Counter Shaft Using A Hammer & DT 46495
Courtesy of GENERAL MOTORS CORP.
16. Install the left side bearing (2) to the counter shaft using DT 46495  (1) and a hammer. See Special Tools .
Fig 10: Counter Shaft Right Side Bearing
Courtesy of GENERAL MOTORS CORP.
17. Install the counter shaft right side bearing.
18. Install the gear unit. Refer to Transmission Assemble .