Component Disassembly & Reassembly: MAINSHAFT: Reassembly

1. Bushings for 1st, 2nd and 3rd gears are sintered iron. Care should be taken when installing these components to prevent damage. Press bushings on separately without hubs. Lubricate all bushings with oil before installing gears. Press 2nd gear bushing onto mainshaft until it bottoms on shoulder. See Fig 1.
2. Press 1st-2nd synchronizer hub onto mainshaft until it bottoms on shoulder. Install 1st-2nd synchronizer keys and springs, if removed. Using arbor press and Bushing Driver (J-22873), press 1st gear bushing on mainshaft until it bottoms on hub. See Fig 2.
3. Install synchronizer ring and 2nd gear on mainshaft, against synchronizer hub. Index synchronizer key slots with keys in hub. Install 3rd gear thrust washer on mainshaft, with tang in shaft slot, against 2nd gear bushing. Using arbor press and Bushing Driver (J-22875), press 3rd gear bushing on mainshaft until it bottoms against thrust washer. See Fig 3.
   Fig 1: Installing 2nd Gear Bushing

   Courtesy of GENERAL MOTORS CORP.
   Fig 2: Installing 1st Gear Bushing

   Courtesy of GENERAL MOTORS CORP.
   Fig 3: Installing 3rd Gear Bushing

   Courtesy of GENERAL MOTORS CORP.
4. Install 3rd gear and 3rd gear synchronizer ring on mainshaft, against 3rd gear thrust washer. Index synchronizer ring key slots with keys. Using arbor press and Bushing Driver (J-5176-D), press 3rd-4th synchronizer hub assembly onto mainshaft, against 3rd gear. See Fig 4. Ensure stepped side of sleeve faces toward front of mainshaft.
5. Retain synchronizer assembly with NEW snap ring. Install reverse driven gear with fork groove toward rear of mainshaft. Install 1st gear on mainshaft, against 1st-2nd synchronizer hub. Install 1st gear thrust washer.

Fig 4: Installing 3rd-4th Synchronizer

Courtesy of GENERAL MOTORS CORP.