Installation of the 3rd and 4th Gear Synchronizer

WARNING: This page is about a different variant/trim than selected.

Install the 3rd gear (1) to the upper main shaft.

Fig 1: Identifying 3rd Gear
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Install the 3 NEW 3rd gear blocking rings (1, 2, 3)

Fig 2: Identifying 3rd Gear Blocking Rings
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NOTE: Make sure that the blocking rings fit.
- Intermediate blocking ring (2) must fit correctly into the 3rd gear (lower arrow).
- Outer blocking ring (1) and inner blocking ring (3) must fit correctly together (upper arrow).
Disassemble the NEW 3rd and 4th gear synchronizer.

Fig 3: Identifying 3rd And 4th Gear Synchronizer Sleeve With Synchronizer Inserts
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1. Remove the NEW 3rd and 4th gear synchronizer sleeve (1).
2. Remove the 3 NEW synchronizer inserts (2, 3) from the synchronizer hub.
Install the NEW 3rd and 4th gear synchronizer hub (2) to the upper main shaft. Press on the synchronizer hub, using the DT-46759 sleeve (1).

Fig 4: Identifying 3rd And 4th Gear Synchronizer Hub
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NOTE: Make sure that the blocking ring fits.

Before pressing, the blocking ring must be aligned to the hub (arrows).
Install the NEW 3rd and 4th gear synchronizer hub retaining ring (1) to the upper main shaft, using the GE-396 pliers.

Fig 5: Identifying 3rd And 4th Gear Synchronizer Hub Retaining Ring
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Install the 3 NEW synchronizer inserts (1) to the NEW 3rd and 4th gear synchronizer hub.

Fig 6: Identifying Synchronizer Inserts
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Install the NEW 3rd and 4th gear synchronizer sleeve (2) to the NEW 3rd and 4th gear synchronizer hub.
NOTE: Make sure that the position of the synchronizer sleeve is correct.

The pits in the synchronizer sleeve (arrow) must be installed in the position of the inserts.
Install the 3 NEW 4th gear blocking rings (1) to the upper main shaft.

Fig 7: Identifying 4th Gear Blocking Rings
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Install the 4th gear bearing (1) to the upper main shaft.

Fig 8: Identifying 4th Gear Bearing
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Install the 4th gear (1) to the upper main shaft.

Fig 9: Identifying 4th Gear
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NOTE: Make sure that the synchronizer ring fits.

Turn the 4th gear. Turning the gear secures correct fitting of the blocking ring into the gear (arrow).
Install the NEW upper main shaft bearing (2). Press on the bearing, using the DT-60000-60 installer (1) with function side "B".

Fig 10: Identifying Upper Main Shaft Bearing And DT-60000-60 Installer
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Measure the fitting of the NEW retaining ring (1). Try different thicknesses of retaining ring.

Fig 11: Identifying Retaining Ring
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- Retaining ring must NOT fit loosely into the groove.
- Use the thickest retaining ring possible.
Install a NEW retaining ring to the upper main shaft, using the GE-396 pliers.
Perform function check.

Fig 12: Identifying 3rd And 4th Gear Synchronizer Sleeve And Reverse Gear Synchronizer Sleeve
Courtesy of GENERAL MOTORS COMPANY
1. Check free rotating of all gears.
2. Shift all gears.
  - 3rd and 4th gear synchronizer sleeve (1)
  - Reverse gear synchronizer sleeve (2)
3. Shift upper main shaft into neutral.