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.
- Lubricate all components in transmission fluid before installation.
- Make sure the oil hole in the collar is 90 degrees from the oil hole in the output shaft.
- Install the thrust washer using the J 24433 and a hydraulic press.
- Install the collar using the J 24433 and a hydraulic press.
- Install the caged needle bearings (3).
- Install the reverse gear (2).
- Install the reverse gear blocking ring (1).
- The raised center hub of the 5th/Reverse synchronizer assembly faces the 5th gear.
- Line up the blocking ring tabs and the hub keyways while pressing.
- Install the 5th/Reverse synchronizer using the J 24433 and a hydraulic press.
- Install the bearing collar using an appropriate tool and a hydraulic press.
- Install the 5th gear blocking ring (3).
- Install the two caged needle bearings (2).
- Install the 5th gear (1).
- Install the 3rd gear using the J 24433 and a hydraulic press.
- Install the 4th gear using the J 24433 and a hydraulic press.
IMPORTANT:
IMPORTANT:
IMPORTANT:
The 3rd gear will install very tight. Ensure that the mating surfaces are clean.
IMPORTANT:
The 4th gear will install very tight. Ensure that the mating surfaces are clean.