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Home >> Chevrolet >> 2006 >> Silverado 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 51 (Transfer Case - NVG 263-NP1 - Overhaul) >> Repair Instructions >> Cleaning and Inspection >> Shift System Components

Shift System Components

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  1. Clean the following shift system components in cleaning solvent and air dry:
    • The high/low shift fork (1)
    • The range sleeve (2)
    • The two/four wheel drive mode shift fork (3)
    • The shift fork shaft (4)
    • The control actuator lever shaft (5)
    • The synchronizer assembly (6)
    Fig 1: Identifying Shift System Components
    GM1578750Courtesy of GENERAL MOTORS CORP.
  2. Inspect the shift fork shaft for straightness (4).
  3. Replace the shift fork shaft if it is not straight.
  4. Inspect the pads (1) on the high/low shift fork for wear.
    Fig 2: Identifying High/Low Shift Fork Inspection Areas
    GM812475Courtesy of GENERAL MOTORS CORP.
  5. Inspect the pin (2) on the shift fork for wear.
  6. Replace the shift fork if the pin is worn or the pads are worn.
    7. IMPORTANT: Only disassemble the shift fork assembly if replacing a faulty component.
    Fig 3: Identifying Inspection Areas On Shift Fork Assembly
    GM812477Courtesy of GENERAL MOTORS CORP.
  7. Inspect the following components of the shift fork assembly for wear or damage:
    • The spring (2)
    • The washers (3)
    • The bracket (4)
    • The shift fork (1)
  8. Inspect the two/four wheel drive mode shift fork roller (1) for the following conditions:
    Fig 4: Identifying Inspection Areas On Two/Four Wheel Drive Mode Shift Fork
    GM812479Courtesy of GENERAL MOTORS CORP.
    • Wear
    • Rotates easily
  9. Inspect the shift fork for worn wear pads (3).
  10. Inspect the shift fork bearing (2) for being faulty.
  11. Replace the shift fork if the above conditions are found.
  12. Inspect the range sleeve for chipped or excessive worn teeth (1).
    Fig 5: Identifying Inspection Areas On Range Sleeve
    GM801271Courtesy of GENERAL MOTORS CORP.
  13. Inspect the shift fork collar (2) on the range sleeve for wear.
  14. Inspect the inner splines (3) of the range sleeve for excessive looseness on the rear output shaft.
  15. Replace the range sleeve if the above conditions are found.
  16. Inspect the high/low shift fork roller slot (2) on the control actuator lever shaft for wear or roughness.
    Fig 6: Inspecting Control Actuator Lever Shaft
    GM887285Courtesy of GENERAL MOTORS CORP.
  17. Inspect the bearing (1) and the seal surface on the control actuator lever shaft for the following conditions:
    • Pitted
    • Wear
    • Corrosion
  18. Inspect the two/four wheel drive mode shift fork cam lobes (3) on the control actuator lever shaft for wear or roughness.
  19. Inspect the detent plunger cam lobes (4) for wear or roughness.
  20. Replace the control actuator lever shaft if any of the above conditions are found.
  21. Inspect the inner synchronizer ring (1) for wear and roughness.
    Fig 7: Exploded View Of Synchronizer Assembly
    GM812463Courtesy of GENERAL MOTORS CORP.
  22. Inspect the middle synchronizer ring (2) friction material for wear or damage.
  23. Inspect the outer synchronizer ring (3) for wear.
  24. Inspect the synchronizer sleeve (4) for the following conditions:
    • Wear on the engagement teeth
    • Wear in the insert notches
  25. Inspect the synchronizer hub (6) for the following conditions:
    • Loose fit on the rear output shaft
    • Broken or damaged insert springs (5 and 8)
    • Worn inserts (7)
  26. Replace the synchronizer assembly if any of the above parts are faulty.
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