GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 Transmission/Transaxle 🢒 Manual Transaxle - MU3 🢒 Input Shaft Assemble

Tools Required

    • 78 41 067 Sleeve Inner Driver
    • 87 91 204 Output Shaft Bearing Race Sleeve
    • 87 91 261 Output Shaft Remover
    • 87 92 202 Output Shaft Bearing Race Sleeve

    Object Number: 895145 Size: SH

    Important: Lubricate all rotating parts and bearings with manual transaxle lubricant P/N 21018899 during assembly.

  1. Install the 3rd gear bearing assembly, 3rd drive gear, and 3rd gear blocking ring.

    2. Object Number: 1227200 Size: SH

    Important: Install the hub with the synchronizer hub washer groove facing up.

  2. Install the 3rd/4th gear synchronizer hub using the 87 91 204 and 87 92 202 . Align the gaps in the synchronizer hub with the blocking ring lugs.

    3. Object Number: 895149 Size: SH
  3. Install the 3rd/4th gear synchronizer hub washer and retaining ring. The square edge on the retaining ring faces up, towards 4th gear.
  4. Measure the clearance between the 2nd and 3rd drive gears.

    5. Specification
    The tighten standard is 0.05-0.4 mm (0.002-0.015 in).


    Object Number: 895140 Size: SH
  5. Install the 3rd/4th gear synchronizer springs and pins.

    6. Object Number: 895152 Size: SH

    Important: The tall teeth on the 3rd/4th synchronizer sleeve must align with the deep tooth gaps in the synchronizer hub.

  6. Install the 3rd/4th synchronizer sleeve onto the synchronizer hub.

    7. Object Number: 895153 Size: SH

    Important: Do not move the synchronizer sleeve after installing detent inserts. The inserts will not stay in position if the sleeve is moved. Only move the sleeve after installing the 4th drive gear.

  7. Move the 3rd/4th gear synchronizer sleeve down, towards 3rd gear, far enough to install the synchronizer detent inserts. Use a small screwdriver to depress the pins and springs, and install the detent inserts.

    8. Object Number: 895137 Size: SH
  8. Install the 4th gear blocking ring to the synchronizer hub.
  9. Install the 4th gear bearing assembly and the 4th drive gear.
  10. Hold down the 4th gear and move the synchronizer sleeve up and down to check for proper operation.

    11. Object Number: 1227202 Size: SH
  11. Press on the new input shaft bearing, next to the 4th drive gear, using the 78 41 067 . Support the shaft under the 2nd drive gear.

    12. Object Number: 895479 Size: SH

    Notice: When installing a new bearing retaining ring, open the ring only as far as necessary to fit the ring over the shaft. Opening the ring too far will damage it.

  12. Install a new bearing retaining ring. Make sure the chamfered edge on the ring is facing up, away from the bearing.

    13. Object Number: 895156 Size: SH
  13. Measure the clearance between the 4th drive gear and input shaft bearing.

    14. Specification
    The tighten standard is 0.02-0.4 mm (0.002-0.015 in).

  14. Press on the new input shaft bearing, next to the 1st drive gear, using the sleeve from the 87 91 261 .