Intermediate Shaft Disassemble

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.

Tools Required

J 36513 Gear and Bearing Separator Plate. See Special Tools and Equipment .
J 44383 Countershaft Bearing Installer. See Special Tools and Equipment .

Press off the 1st gear assembly and the 2nd gear assembly as a unit, from the intermediate shaft using the J 36513 (1), the J 44383 (2) and a hydraulic press.

Fig 1: Pressing Off 1st & 2nd Gear Assemblies
Courtesy of GENERAL MOTORS CORP.

Fig 2: Exploded View Of 1st And 2nd Gear Assemblies

Courtesy of GENERAL MOTORS CORP.

Put the 1st gear assembly and the 2nd gear assembly, as a unit, on the bench.
Remove the thrust washer (1).
Remove the roller bearing (2).
Remove the 1st gear (3).
Remove the roller bearing (4).
Remove the bearing collar (5).
Remove the thrust washer (6).

Fig 3: Exploded View Of 1st Gear Assembly

Courtesy of GENERAL MOTORS CORP.

Remove the 1st gear inner cone (1).
Remove the 1st gear blocking ring (2).
Remove the 1st gear outer cone (3).
Remove the 1st/2nd synchronizer assembly (4).

Fig 4: Exploded View Of 2nd Gear Assembly

Courtesy of GENERAL MOTORS CORP.

Remove the 2nd gear outer cone (1).
Remove the 2nd gear blocking ring (2).
Remove the 2nd gear inner cone (3).
Remove the 2nd gear.

Fig 5: Removing Caged Needle Bearings

Courtesy of GENERAL MOTORS CORP.

Remove the caged needle bearings from the intermediate shaft.