GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Spark 🢒 Transmission/Transaxle 🢒 Manual Transmission - Y4M 🢒 Synchronizer Assembly Inspection

    Object Number: 1223795 Size: SH
  1. Inspecting wear of cone area. After matching synchronizer ring to gear, measure as shown in figure. Replace if it is below limit.

    2. Specifications:

    • The standard clearance between the gear and ring is 1 mm (0.039 in).
    • The clearance limit between the gear and ring is 0.5 mm (0.020 in).

    Object Number: 1223803 Size: SH
  2. Inspecting cone contact condition. When synchronizer mechanism is abnormal in operation, connection between ring inner surface and gear cone area is considered to be partially defective in spite of correct clearance between gear and ring. Therefore, cone area and ring inner surface shall be inspected. In this case, ring inner surface shall be glossy. Black area is abnormal and if inspection is difficult, inspect after applying red lead. Cone area can be worn in wave form.

    3. Object Number: 1223775 Size: SH
  3. Inspecting key slot width of synchronizer ring. Measure key slot width of synchronizer ring. Replace if it exceeds the limit.

    4. Specifications:

    • The standard key slot width for 1st gear is 8.2 mm (0.323 in).
    • The limit key slot width for 1st gear is 8.6 mm (0.339 in).
    • The standard key slot width for 2nd, 3rd, and 4th gear is 9.6 mm (0.378 in).
    • The limit key slot width for 2nd, 3rd, and 4th gear is 10 mm (0.394 in).
    • The standard key slot width for 5th gear is 9.4 mm (0.370 in).
    • The limit key slot width for 5th gear is 9.8 mm (0.386 in).

    Object Number: 1223784 Size: SH
  4. Inspect for worn or damaged synchronizer ring teeth. Replace it if necessary.

    5. Object Number: 1223790 Size: SH
  5. Inspect for worn synchronizer key (2).
  6. Inspect for weak, damaged or broken spring (1).