Synchronizers Cleaning and Inspection. Chevrolet Camaro 2002

For 1990-2009 cars only

Makes 🢒 Chevrolet 🢒 2002 🢒 Camaro 🢒 Transmission/Transaxle 🢒 Manual Transmission - M49 🢒 Synchronizers Cleaning and Inspection

Cleaning and Inspection Procedure

Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.
Clean all the synchronizer parts with solvent.
Air dry all the synchronizer parts.
Inspect the synchronizer parts for the following conditions:

•

Burrs

•

Cracks

•	Chamfer for excessive wear

•	Free movement of the clutching sleeves on their hubs

•	Worn or damaged clutch teeth

The 1st/2nd speed outer cone and the 3rd/4th speed blocking ring are lined with friction material. The friction material cannot be checked visually for wear.

Replace synchronizer parts that are worn or damaged.

Replace a burred or nicked part that cannot be reconditioned by hand. Use a soft stone or crocus cloth.

Inspect the brass 5th speed gear blocking ring for wear and damage.

Notice: Make certain the blocker rings are correctly identified before assembly. The 1st/2nd synchronizer blocker ring does not have friction material. The 3rd/4th synchronizer blocker ring has friction material. Assembling one blocker ring in place of the other will result in serious damage to the transmission.

Assemble the 3rd speed gear blocking ring to the 3rd speed gear. Use a twisting motion in order to fully seat the parts.

Measure the gap between the vertical faces of the 3rd speed gear blocking teeth and the clutch teeth using a feeler gauge.

The nominal gap is 0.88-1.50 mm (0.035-0.059 in) for new blocking rings.

Replace the blocking ring and the 3rd speed gear when the gap is significantly less than specified.

Assemble the 4th speed gear blocking ring to the main drive gear. Use a twisting motion in order to fully seat the parts.

Measure the gap between the vertical faces of the 4th speed gear blocking teeth and the clutch teeth using a feeler gauge.

The nominal gap is 0.88-1.50 mm (0.035-0.059 in) for new blocking rings.

Replace the blocking ring and the 4th speed gear when the gap is significantly less than specified.

Assemble the following parts using a twisting motion in order to fully seat them:

11.1.

The needle bearing assembly to the 1st speed gear

11.2.

The needle bearing sleeve

11.3.

The three-piece 1st speed gear blocking ring assembly

Measure the gap between the vertical faces of the blocking teeth and the clutch teeth using a feeler gauge.

The nominal gap is 0.81-1.40 mm (0.032-0.05 in) for new blocking rings.

Replace the blocking ring and the 1st speed gear when the gap is significantly less than specified.

Assemble the following parts using a twisting motion in order to fully seat them:

13.1.

The thrust washer to the 2nd speed gear

13.2.

The three-piece 2nd speed gear blocking ring assembly

Measure the gap between the vertical faces of the blocking teeth and the clutch teeth using a feeler gauge.

The nominal gap is 0.81-1.40 mm (0.032-0.055 in) for new blocking rings.

Replace the blocking ring and the 2nd speed gear when the gap is significantly less than specified.

Examine the fit between the hub and the sleeve of each synchronizer. An excessively tight or loose hub-to-sleeve fit will cause hard shifting.

Examine the clutching teeth for evidence of gear clash.

Examine the clutching teeth for gear hop-out.