LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 261 (Manual Transmission - GETRAG (M86) - Overhaul) >> Repair Instructions >> Input Shaft Assemble >> Assembly Procedure

Assembly Procedure

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2004 Saturn Ion 3, 2004 Saturn Ion 2, 2004 Saturn Ion 1, 2004 Pontiac Sunfire, and 2004 Pontiac Grand Am. However, it is still accessible from the selected car via links, so may be relevant.
    IMPORTANT:
    • Lubricate all components with transmission fluid before installation.
    • The machined surface faces the needle thrust bearing.
    Fig 1: Installing 5th Gear Using J 24433
    GM514867Courtesy of GENERAL MOTORS CORP.
  1. Install the 5th gear using J 24433  and a hydraulic press.
    2. Fig 2: View Of Caged Needle Bearing & Thrust Bearing
    GM514868Courtesy of GENERAL MOTORS CORP.
  2. Install the thrust bearing (2).
  3. Install the two caged needle bearings (1).
    4. Fig 3: Exploded View Of Input Shaft Assembly
    GM901605Courtesy of GENERAL MOTORS CORP.
  4. Install the 3rd gear (5).
  5. Install the wavy washer (4).
  6. Install the 3rd gear blocking ring (3).
  7. Install the thrust bearing (2).
    8. IMPORTANT: Use a NEW thrust washer.
  8. Install a new thrust washer (1).
    9. IMPORTANT:
    • The machined surface of the synchronizer faces the thrust washer.
    • Make sure to align the slots in the synchronizer with the gear blocking ring tabs.
    Fig 4: Installing 3rd/4th Gear Synchronizer Assembly
    GM514871Courtesy of GENERAL MOTORS CORP.
  9. Install the 3rd/4th synchronizer using the J 24433  and a hydraulic press.
    10. IMPORTANT: Make sure the oil hole on the bearing collar is 90 degrees from the oil hole in the shaft.
    Fig 5: View Of Bearing Collar
    GM514872Courtesy of GENERAL MOTORS CORP.
  10. Install the bearing collar using an appropriate tool and a hydraulic press.
    11. Fig 6: Exploded View Of Input Shaft
    GM901603Courtesy of GENERAL MOTORS CORP.
  11. Install the 4th gear blocking ring (6).
  12. Install the wavy washer (5).
  13. Install the caged needle bearing (4).
  14. Install the 4th gear (3).
    15. IMPORTANT: The pocketed side of the thrust bearing (2) faces the thrust washer.
  15. Install the thrust bearing (2).
  16. Install the thrust washer (1).
scientia non olet · About LEMON Manuals