Now a days, gear shift system of passenger car manual transmissions demands superior performance with particular emphasis on low effort, short travel & positive gear engagement feel. To meet these requirements, a high capacity multiple cone synchronizers coated with high co-efficient of friction material are used. The design of new synchronizer with these specifications is largely influenced by torsional fluctuations from engine caused due to low stiffness of clutch springs. Excessive torsional vibrations input to transmission leads to wobbling of synchro rings within the clearances with surrounding parts. Wobbling leads to abrasion wear of frictional material from synchro ring causing grating or crashing of gears during shifting. Deletion of lining material and change of base material for synchrorings are outcome of this study. The same is validated through testing on bench. This paper presents the optimization of the multiple cone synchronizer design exposed to excessive torsional vibrations & validation of the same on test bench during design stage itself instead vehicle level validation.