GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Spark 🢒 Transmission/Transaxle 🢒 Manual Transmission - Y3S 🢒 Input Shaft Assemble
    • DT 46495 (DW09925-98221) Gear, Bearing Installer
    • DT 46496 (DW09940-53111) Gear, Bearing Installer

    Object Number: 1223799 Size: SH
  1. Install the 3rd gear synchronizer ring (1).

    2. Important: Coat the inner parts: gear, bearing, oil seal etc., with gear fluid.

  2. Install the 3rd gear bearing (2).

    3. Object Number: 1223772 Size: SH
  3. Install the 3rd-4th synchronizer springs to the hub.

    4. Important: In case of assembling the synchronizer sleeve and the hub, let A=B.

  4. Install the 3rd-4th synchronizer key to the hub.
  5. Install the 3rd-4th hub (2) to the sleeve (1).

    6. Object Number: 1223783 Size: SH

    Important: Position the longer flange of the hub toward the 3rd gear and match the key and the ring groove.

  6. Insert the 3rd-4th hub assembly into the input shaft (2).
  7. Install the 3rd-4th hub assembly using a hammer and the DT 46496  (1).

    8. Object Number: 1223789 Size: SH

    Important: Do not overpress when installing the gear bearing and hub assembly. If overpressed, the gear, teeth may be damaged.

  8. When installing gear, bearing and hub assembly, install them slowly using the DT 46496 and a hammer. If overpressed, the gear teeth may be damaged.

    9. Object Number: 1223752 Size: SH

    Important: Match the ring groove to the key of hub.

  9. Install the 3rd-4th synchronizer clip.

    10. Object Number: 1223767 Size: SH
  10. Install the input shaft 4th gear bearing (2) and the 4th gear (1).

    11. Object Number: 1223780 Size: SH
  11. Install the 5th gear spacer (2) using the DT 46495  (1) and a hammer.
  12. Install the 3rd-4th Input shaft left side bearing using the DT 46495 and a hammer.

    13. Object Number: 1223788 Size: SH
  13. Install the input shaft right side bearing to the input shaft using the DT 46495 and a hammer (1).
  14. Install the gear unit. Refer to Transmission Replacement .