1992 Saturn SL2 AutomaticFACTORY OEM SERVICE PROCEDURE

5TH Gear & 5TH-Reverse Synchronizer Assembly: Installation

  1. Install 5th input and output shaft gears. Install 5th gear synchronizer ring and spring to 5th gear. Install 5th-reverse shift fork on synchronizer assembly sleeve.
  2. Install 5th-reverse synchronizer assembly while sliding shift fork over shift rail. Ensure synchronizer ring tabs align with slots in synchronizer hub. Install new 5th-reverse shift fork retaining clip.
  3. Install synchronizer spring on reverse synchronizer ring and install assembly on 5th-reverse synchronizer sleeve. Install reverse cone and washer. Shift 5th-reverse fork into reverse position; transaxle is now in 2 gears.
  4. Install input and output shaft nuts and tighten to specification. Move all shift forks to neutral position. To complete installation, reverse removal procedure. See REAR COVER  under ON-VEHICLE SERVICE.
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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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