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Home >> Chevrolet >> 2015 >> Cruze LT, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Manual Transmission - M32) >> Repair Instructions - On Vehicle >> 3rd and 4th Gear Synchronizer Replacement >> Shimming Procedure

Shimming Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Turn the clutch housing along with the DT-6115  holder (1) 180 degrees. Clutch side facing upwards.
    Fig 1: Identifying DT-6115 Holder
    GM4081150Courtesy of GENERAL MOTORS COMPANY
  2. Secure with pin (2).
  3. Remove the clutch actuator cylinder pipe (2) from the clutch actuator cylinder pipe sleeve (1). Push the lashes in direction of the arrows to release the pipe.
    Fig 2: Clutch Actuator Cylinder Pipe And Clutch Actuator Cylinder Pipe Sleeve
    GM4067582Courtesy of GENERAL MOTORS COMPANY
  4. Clutch Actuator Cylinder Bolt (2) »Remove and DISCARD [3x]
    Fig 3: Identifying Clutch Actuator Cylinder Bolts
    GM4081151Courtesy of GENERAL MOTORS COMPANY
  5. Clutch Actuator Cylinder (1) »Remove
  6. Turn the clutch housing along with the DT-6115  holder 180 degrees. Transmission side facing upwards.
    Fig 4: Identifying Input Shaft Seal Ring
    GM4081152Courtesy of GENERAL MOTORS COMPANY
  7. Secure the DT-6115  holder with the pin.
  8. Remove and DISCARD the input shaft seal ring (1), using a arbor and a hammer.
  9. Disassemble the DT-60000-130  support
    Fig 5: Identifying DT-60000-130-2 Spacer And DT-60000-130-3 Support
    GM4081155Courtesy of GENERAL MOTORS COMPANY
    1. Remove the 2 DT-60000-130-2  spacer (2).
    2. Remove the 3 DT-60000-130-3  support (1).
  10. Install the DT-60000-135  adapter
    Fig 6: Locating DT-60000-135-3 Grub Screw, DT-60000-135-1 Adapter Plate, DT-60000-130-3 Support And DT-60000-135-2 Spacer
    GM4081156Courtesy of GENERAL MOTORS COMPANY
    1. Install the DT-60000-135-3  grub screw (4) to the DT-60000-130  plate.
    2. Position the DT-60000-135-1  adapter plate (1) on the DT-60000-130  plate.
    3. Install the 3 DT-60000-130-3  support (3) to the DT-60000-130  plate.
    4. Install the 2 DT-60000-135-2  spacer (2) to the DT-60000-130  plate.
  11. Install the transmission case (1) to the DT-60000-130  support (3). Install the 2 washers and 2 nuts (2, 4) and tighten.
    Fig 7: Identifying Transmission Case, DT-60000-130 Support, Washers And Nuts
    GM4081157Courtesy of GENERAL MOTORS COMPANY
  12. Turn the supports (1, 2) counterclockwise and hand tighten.
    Fig 8: Identifying Supports
    GM4081162Courtesy of GENERAL MOTORS COMPANY
  13. Mark the positions of the shafts to relief the following steps.
    Fig 9: Marking Positions Of Shafts
    GM4081170Courtesy of GENERAL MOTORS COMPANY
    NOTE: Use a permanent marker.
    • I = Input shaft
    • II = Upper main shaft
    • III = Lower main shaft
  14. Install the DT-60000-85  remover to the bearing cup.
    Fig 10: Identifying Special Nut
    GM4081172Courtesy of GENERAL MOTORS COMPANY
    1. Position the DT-60000-85  remover to the bearing cup.
    2. Turn the nut (1) in the respective direction to reach the correct depth of the cone (arrow).
    3. Hold the spindle with a 8 mm open-end wrench (3) and turn the special nut (2) clockwise in order to spread the cone beneath the bearing cup (arrow).
  15. Remove the bearing cup (4).
    Fig 11: Identifying Bearing Cup And Shim Ring
    GM4081173Courtesy of GENERAL MOTORS COMPANY
    NOTE: Make sure that the bail does not shore up at the bearing cup (arrow).
    1. Hold the spindle with a 8 mm open-end wrench (1) and turn the nut clockwise with a 19 mm open-end wrench (2) in order to pull the bearing cup out.
    2. After removal release the bearing cup and the shim ring (3) from the DT-60000-85  remover.
  16. Mark the cups (1) at the position a respectively to their shafts.
    Fig 12: Identifying Cup
    GM4088044Courtesy of GENERAL MOTORS COMPANY
    NOTE: Use a permanent marker.
  17. Repeat the 3 previous steps in order to remove all bearing cups and shim rings (2) from the transmission case.
  18. Keep the bearing cup of the input shaft and the lower main shaft.
  19. DISCARD the bearing cup of the upper main shaft.
  20. DISCARD all shim rings.
  21. Remove the transmission case (1) from the DT-60000-130  support (3).
    Fig 13: Identifying Transmission Case, DT-60000-130 Support, Washers And Nuts
    GM4081157Courtesy of GENERAL MOTORS COMPANY
  22. Re-cut 3 clutch actuator cylinder bolt threads (1) in the clutch housing.
    Fig 14: Identifying Clutch Actuator Cylinder Bolt Threads
    GM4088048Courtesy of GENERAL MOTORS COMPANY
  23. Turn the clutch housing along with the DT-6115  holder 180 degrees. Transmission side facing upwards.
  24. Re-cut 16 transmission case bolt threads (1) in the clutch housing.
    Fig 15: Identifying Transmission Case Bolt Threads
    GM4088049Courtesy of GENERAL MOTORS COMPANY
  25. Clean the sealing surface of the clutch housing and the transmission case from sealant and debris.
    Fig 16: Identifying Openings
    GM4081175Courtesy of GENERAL MOTORS COMPANY
    NOTE: The sealing surfaces must not be treated mechanical (for example with blunt scraper or steel brush). Do not use cleaners that affect plastics, steel or aluminum.
  26. Clean all components.
    NOTE: During cleaning make sure that no cleaner or debris gets into the differential gear. Openings (1, 2, 3) must be closed with lint free cloth or suitable caps.
  27. Dry all components.
  28. Install the upper main shaft (1) and the lower main shaft (2).
    Fig 17: Identifying Upper Main Shaft And Lower Main Shaft
    GM4081108Courtesy of GENERAL MOTORS COMPANY
  29. Input Shaft (1) »Install
    Fig 18: Locating Input Shaft
    GM4081106Courtesy of GENERAL MOTORS COMPANY
  30. Install the shift forks (3, 4).
    Fig 19: Identifying Shift Shafts And Shift Forks
    GM4081104Courtesy of GENERAL MOTORS COMPANY
    NOTE: Shift the synchronizer sleeves to gain space for installation.
  31. Install the shift shafts (1, 2).
  32. Check free rotating of all gears.
  33. Install the 2 marked bearing cups (2) to their respective shaft.
    Fig 20: Identifying Bearing Cups
    GM4081179Courtesy of GENERAL MOTORS COMPANY
    NOTE: The bearing cups must be clean to avoid failure in the following measurement.
  34. Install the NEW bearing cup (1) to the upper main shaft.
  35. Install the 2 DT-60000-125-4  spacer (1, 3) to the clutch housing.
    Fig 21: Identifying Spacers
    GM4081180Courtesy of GENERAL MOTORS COMPANY
    NOTE: The 2 DT-60000-125-4  spacer must be installed on the position of the clutch housing locating pins.
  36. Install the 2 DT-60000-125-3  spacer (2, 4) to the clutch housing.
  37. Install the 3 DT-60000-125-2  adapter (5) to the bearing cups.
    Fig 22: Identifying Cylinders And Adapters
    GM4081182Courtesy of GENERAL MOTORS COMPANY
    NOTE: DT-60000-120-1  cylinder, DT-60000-120-2  cylinder, DT-60000-120-3  cylinder, DT-60000-125-1  adapter and DT-60000-125-2  adapter must be clean at their contact areas to avoid failure in the measurement.
  38. Install the DT-60000-120-1  cylinder (1) to the input shaft.
  39. Install the DT-60000-120-2  cylinder (2) to the upper main shaft.
  40. Install the DT-60000-120-3  cylinder (3) to the lower main shaft.
  41. Install the 3 DT-60000-125-1  adapter (4) to the measuring cylinders.
  42. Turn the DT-60000-120-1  cylinder, DT-60000-120-2  cylinder and DT-60000-120-3  cylinder several times on the transmission shaft bearings.
  43. Install the transmission case (1) to DT-60000-125-3  spacer and the DT-60000-125-4  spacer.
    Fig 23: Identifying Transmission Case
    GM4081185Courtesy of GENERAL MOTORS COMPANY
    NOTE: DT-60000-125-1  adapter and transmission case must be clean at their contact areas. The 3 DT-60000-125-1  adapter must fit into the transmission case bore for the shaft bearings.
  44. Install 4 washers (3) and 4 nuts (2) and cross tighten to 10 N.m (89 lb in).
    CAUTION: Fastener Caution
  45. Turn the transmission shafts.
    Fig 24: Identifying DT-60000-150 Turning Tool
    GM4081186Courtesy of GENERAL MOTORS COMPANY
    1. Install the DT-60000-140  turning tool respectively the DT-60000-150  turning tool (1)
      NOTE: The correct special tool depends on the input shaft diameter at position of the clutch driven plate.
    2. Shift gears, switch shifting of the gears between the upper main shaft and on the lower main shaft. Turn input shaft 20 times in each gear.
    3. Shift the transmission into neutral.
  46. Use a feeler gauge (2) with 0.05 mm (0.002 in) increments to measure the gap at the measuring cylinders.
    Fig 25: Identifying Feeler Gauge
    GM4081188Courtesy of GENERAL MOTORS COMPANY
  47. Measure the gap at the DT-60000-120-1  cylinder (1), DT-60000-120-2  cylinder and DT-60000-120-3  cylinder.
  48. Note the measured values.
  49. Make a second measurement on the opposite side (arrows) at DT-60000-120-1  cylinder (1), DT-60000-120-2  cylinder (1) and DT-60000-120-3  cylinder (1).
    Fig 26: Locating DT-60000-120-1 Cylinder, DT-60000-120-2 Cylinder And DT-60000-123-3 Cylinder
    GM4081189Courtesy of GENERAL MOTORS COMPANY
    NOTE: In case of slight differing values use the smaller value. In case of high differing values check the whole measuring setup.
  50. Note the measured values.
  51. Calculate the thickness of the NEW shim rings:
    • Input shaft: measured value + 0.15 mm (0.006 in) = shim ring thickness
    • Upper main shaft: measured value + 0.3 mm (0.012 in) = shim ring thickness
    • Lower main shaft: measured value + 0.3 mm (0.012 in) = shim ring thickness
  52. Remove the DT-60000-140  turning tool respectively the DT-60000-150  turning tool (1) from the input shaft.
    Fig 27: Identifying DT-60000-150 Turning Tool
    GM4081186Courtesy of GENERAL MOTORS COMPANY
  53. Remove 4 nuts and washers (2, 3).
    Fig 28: Identifying Transmission Case
    GM4081185Courtesy of GENERAL MOTORS COMPANY
  54. Remove the transmission case (1) from the DT-60000-125-3  spacer and the DT-60000-125-4  spacer.
  55. Remove the 3 DT-60000-125-1  adapter (4) from the measuring cylinders.
    Fig 29: Identifying Cylinders And Adapters
    GM4081182Courtesy of GENERAL MOTORS COMPANY
  56. Remove the DT-60000-120-1  cylinder (1), DT-60000-120-2  cylinder (2) and DT-60000-120-3  cylinder (3) from the transmission shafts.
  57. Remove the 3 DT-60000-125-2  adapter (5) from the bearing cups.
  58. Remove the 2 DT-60000-125-3  spacer (2, 4) from the clutch housing.
    Fig 30: Identifying Spacers
    GM4081180Courtesy of GENERAL MOTORS COMPANY
  59. Remove the 2 DT-60000-125-4  spacer (1, 3) from the clutch housing.
  60. Remove the NEW bearing cup (1) from the upper main shaft.
    Fig 31: Identifying Bearing Cups
    GM4081179Courtesy of GENERAL MOTORS COMPANY
  61. Remove the 2 marked bearing cups (2) from their respective shaft.
  62. Install the transmission case (1) to the DT-60000-130  support (3). Install the 2 washers and 2 nuts (2, 4) and tighten.
    Fig 32: Identifying Transmission Case, DT-60000-130 Support, Washers And Nuts
    GM4081157Courtesy of GENERAL MOTORS COMPANY
  63. Turn the supports (1, 2) counterclockwise and hand tighten.
    Fig 33: Identifying Supports
    GM4081162Courtesy of GENERAL MOTORS COMPANY
  64. Install 3 NEW shim rings (1) to the transmission case.
    Fig 34: Identifying Shim Rings
    GM4081190Courtesy of GENERAL MOTORS COMPANY
    NOTE: Make sure to use the measured and calculated shim rings in the correct position.
  65. Install 2 marked bearing cups (1) to the transmission case on the respective positions, using DT-60000-105  installer (3) and DT-523-1  handle (2). Hammer the outer ring completely into the clutch housing till a clarion, metallic sound is to hear.
    Fig 35: Identifying Marked Bearing Cups, DT-60000-105 Installer And DT-523-1 Handle
    GM4088056Courtesy of GENERAL MOTORS COMPANY
  66. Install the NEW bearing cup (4) to the transmission case on the position of the upper main shaft, using DT-60000-105  installer (3) and DT-523-1  handle (2). Hammer the outer ring completely into the clutch housing till a clarion, metallic sound is to hear.
  67. Remove the transmission case (1) from the DT-60000-130  support (3).
    Fig 36: Identifying Transmission Case, DT-60000-130 Support, Washers And Nuts
    GM4081157Courtesy of GENERAL MOTORS COMPANY
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