GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2006 🢒 ION 🢒 Transmission/Transaxle 🢒 Manual Transmission - NV 3500 🢒 Main Shaft Disassemble

Tools Required

    • J 21427-A Speedometer Gear Puller Adapter
    • J 22912-B Split Plate Bearing Puller
    • J 24420-C Harmonic Balancer Puller

    Object Number: 4800 Size: SH
  1. If 2WD vehicle, remove the mainshaft bearing retainer.

    2. Object Number: 4801 Size: SH
  2. Remove the following components from the mainshaft assembly:
    3. • The 2 shift forks (1)
    • The reverse idler gear (2)
    • The countershaft rear bearing (4)
    • The countershaft (3)

    Object Number: 736019 Size: SH
  3. If 2WD vehicle, using the J 21427-A  (2) and the J 24420-C  (1), remove the speed sensor reluctor wheel from the rear of the mainshaft.

    4. Do not reuse the reluctor wheel after removal.


    Object Number: 4803 Size: SH
  4. If 2WD vehicle, remove the mainshaft rear bearing retaining ring (1) and the mainshaft rear bearing (2).

    5. Object Number: 4804 Size: SH
  5. Remove the mainshaft assembly from the input shaft.

    6. Important: Leave the synchronizer ring on the 3rd/4th synchronizer assembly to prevent the synchronizer detent balls from popping out.

  6. Remove the 4th gear synchronizer blocking ring and put on the 4th gear synchronizer assembly.
  7. Remove the mainshaft front bearing from the input shaft.

    8. Object Number: 4808 Size: SH
  8. Remove the 3rd/4th gear synchronizer retaining ring.

    9. Object Number: 4810 Size: SH
  9. Scribe an alignment mark on the synchronizer hub and the synchronizer sleeve in order to properly reassemble the synchronizer hub assembly.

    10. Object Number: 38500 Size: SH

    Important: When removing the synchronizer hubs use the J 22912-B under the gear for that synchronizer and not the synchronizer sleeve. Do not separate the synchronizer hub from the synchronizer sleeves. Leave the synchronizer rings with the synchronize assembly to prevent the synchronizer detent balls from popping out.

  10. Using a hydraulic press and the J 22912-B remove the 3rd/4th speed gear synchronizer hub assembly, the third speed gear and the synchronizer rings.
  11. Remove the synchronizer assembly from the third gear.

    12. Object Number: 4745 Size: SH
  12. Remove the 3rd speed gear needle bearing assembly (1).

    13. Object Number: 1705360 Size: SH
  13. Remove the following components:
    14. 13.1. The 2nd speed gear 2 piece thrust washer
    13.2. The retainer ring

    Object Number: 1705359 Size: SH
  14. Remove the following components:
    15. 14.1. The 2nd speed gear (1)
    14.2. The 2nd speed gear needle bearing assembly (2)

    Object Number: 1705358 Size: SH
  15. Remove the following components for the 2nd gear synchronizer:
    16. 15.1. The synchronizer cone
    15.2. The blocker ring
    15.3. The reaction cone

    Object Number: 1705356 Size: SH
  16. Remove the 1st/2nd gear synchronizer retaining ring from the mainshaft.
  17. Remove the 2nd gear sychronizer interim ring.

    18. Object Number: 626287 Size: SH
  18. Scribe an alignment mark on the synchronizer hub and the synchronizer sleeve in order to properly reassemble the synchronizer hub assembly.

    19. Important: When removing the synchronizer hubs use the J 22912-B under the gear for that synchronizer and not the synchronizer sleeve. Do not separate the synchronizer hub from the synchronizer sleeves. Leave the synchronizer rings with the synchronize assembly to prevent the synchronizer detent balls from popping out.

  19. Using a hydraulic press and the J 22912-B remove the 1st/2nd speed gear synchronizer hub and the 1st speed gear.

    20. Object Number: 4740 Size: SH
  20. Remove the following components:
    21. 20.1. The synchronizer cone (5)
    20.2. The blocker ring (4)
    20.3. The reactor cone (3)
    20.4. The synchronizer interim ring (2)
    20.5. The 1st speed gear (1)

    Object Number: 4811 Size: SH
  21. Remove the 1st speed gear needle bearing assembly.

    22. Object Number: 4739 Size: SH
  22. Turn the mainshaft over to work on the output end.
  23. Remove the following components:
    24. 23.1. The 5th speed gear (3)
    23.2. The 5th speed gear needle bearing assembly (1). The needle bearing is split in order to remove it over the collar.

    Object Number: 7906 Size: SH
  24. Remove the retaining ring for the 5th/Reverse synchronizer hub from the mainshaft.

    25. Object Number: 850032 Size: SH
  25. Scribe an alignment mark on the synchronizer hub and the synchronizer sleeve in order to properly assemble the synchronizer hub assembly.

    26. Important: When removing the synchronizer hubs, use the J 22912-B under the gear for that synchronizer, not the synchronizer sleeve. Do not separate the synchronizer hub from the synchronizer sleeves. Keep the synchronizer rings with the synchronizer assembly to prevent the synchronizer detent balls from popping out.

  26. Using a hydraulic press and the J 22912-B , remove the 5th/Reverse speed gear synchronizer assembly (1) and the reverse speed gear (2).

    27. Object Number: 4735 Size: SH
  27. Remove the reverse speed gear needle bearing assembly (1).

    28. Object Number: 626291 Size: SH
  28. Remove the reverse speed gear drag seal.