Removal of the 3rd and 4th Gear Synchronizer

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

Clean the upper main shaft (2) very accurate, clean the hollow shaft from the inside (arrow). Use a part cleaner (1) and compressed air.

Fig 1: Identifying Upper Main Shaft
Courtesy of GENERAL MOTORS COMPANY

NOTE: Remaining residue may lead to transmission failure.
Dry the upper main shaft.
Remove and DISCARD the retaining ring (1) from the upper main shaft, using the GE-396 pliers.

Fig 2: Identifying Retaining Ring
Courtesy of GENERAL MOTORS COMPANY

NOTE: Some transmissions do NOT have this retaining ring.
Cut in the bearing cage (2) of the upper main shaft bearing in several places on the top, using side cutting pliers (1).

Fig 3: Identifying Bearing Cage
Courtesy of GENERAL MOTORS COMPANY
Cut in the bearing cage (2) of the upper main shaft bearing in several places on the bottom, using side cutting pliers (1). If necessary, use a screwdriver (3) to lift the cage.

Fig 4: Locating Bearing Cage
Courtesy of GENERAL MOTORS COMPANY
Remove and DISCARD the cage.
Remove and DISCARD all rollers.
Install the DT-60000-10 remover (1) to the bearing inner ring (2) of the upper main shaft, make sure of proper seat (arrow).

Fig 5: Identifying DT-60000-10 Remover And Outer Bearing Inner Ring
Courtesy of GENERAL MOTORS COMPANY
Tighten 2 nuts of the DT-60000-10 remover.
Support the bearing inner ring (3), using the DT-60000-10 remover (1).

Fig 6: Identifying Outer Bearing Inner Ring, DT-60000-10 Remover And CH-500-5 Arbor
Courtesy of GENERAL MOTORS COMPANY
Remove the bearing inner ring from the upper main shaft. Press out the upper main shaft, using the CH-500-5 arbor (2).
NOTE: Hold the upper main shaft before pressing is finished, the upper main shaft must not fall to the floor.
Remove the DT-60000-10 remover (1) from the bearing inner ring (2).

Fig 7: Identifying DT-60000-10 Remover And Inner Bearing Inner Ring
Courtesy of GENERAL MOTORS COMPANY
DISCARD the bearing inner ring.
Remove the 4th gear (1) from the upper main shaft.

Fig 8: Identifying 4th Gear And Bearing
Courtesy of GENERAL MOTORS COMPANY
Remove the 4th gear bearing (2) from the upper main shaft.
Remove and DISCARD the 3 4th gear blocking rings (1) from the upper main shaft.

Fig 9: Identifying 4th Gear Blocking Rings
Courtesy of GENERAL MOTORS COMPANY
Remove and DISCARD the 3rd and 4th gear synchronizer sleeve (2) from the 3rd and 4th gear synchronizer hub.

Fig 10: Identifying 3rd And 4th Gear Synchronizer Sleeve And Synchronizer Inserts
Courtesy of GENERAL MOTORS COMPANY
Remove and DISCARD 3 synchronizer inserts (1, 3) from the synchronizer hub.
Remove and DISCARD the 3rd and 4th gear synchronizer hub retaining ring (1) from the upper main shaft, using the GE-396 pliers.

Fig 11: Identifying 3rd And 4th Gear Synchronizer Hub Retaining Ring
Courtesy of GENERAL MOTORS COMPANY
Support the 3rd gear (3), using the DT-307-B plate (1).

Fig 12: Identifying DT-307-B Plate
Courtesy of GENERAL MOTORS COMPANY
Remove the 3rd and 4th gear synchronizer hub (2) and the 3rd gear from the upper main shaft. Press out the upper main shaft.
NOTE: Hold the upper main shaft before pressing is finished, the upper main shaft must not fall to the floor.
Remove the 3rd and 4th gear synchronizer hub (2) and the 3 3rd gear blocking rings (1) from the 3rd gear.

Fig 13: Identifying 3rd And 4th Gear Synchronizer Hub With 3rd Gear Blocking Rings
Courtesy of GENERAL MOTORS COMPANY

DISCARD the hub and the blocking rings.
Check all components of the upper main shaft for damage.
- Damaged parts must not be installed.