LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2006 >> Silverado 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 52 (Manual Transmission - NV 3500 - Overhaul) >> Repair Instructions >> Transmission Assemble

Transmission Assemble

WARNING: This page is about a different variant/trim than selected.

Tools Required

  1. If 4WD vehicle, install the rear case assembly.
    Fig 1: Installing Rear Case Assembly (4WD)
    GM4799Courtesy of GENERAL MOTORS CORP.
    1. Ensure the reverse idler shaft is lined up with the hole in the case.
    2. Rotate the case back and forth while pulling down.
  2. If 4WD vehicle, install a new main shaft rear bearing retaining ring.
    Fig 2: Installing Main Shaft Rear Bearing Retaining Ring (4WD)
    GM7910Courtesy of GENERAL MOTORS CORP.
  3. If 2WD vehicle, install the following components:
    1. Install the J 36515-10  through the bolt holes in the rear housing. See Special Tools .
      Fig 3: Using J 36515-10 To Position Mainshaft Bearing Retainer For Assembly
      GM761098Courtesy of GENERAL MOTORS CORP.
    2. Screw the threaded cable ends into the mainshaft bearing retainer.
    3. Position the notch in the bearing retainer towards the oil delivery tube assembly.
  4. Fill the countershaft rear bearing race with J 36850  or equivalent.
  5. If 2WD vehicle, install the rear case assembly.
    1. Ensure the reverse idler shaft is lined up with the hole in the case.
    2. Align the shift forks shift rail opening with the rear case.
    3. Rotate the case back and forth while pulling down.
    4. Pull up on the J 36515-10  while installing the rear case. See Special Tools .
      Fig 4: Pulling On J 36515-10 While Installing Rear Case
      GM4755Courtesy of GENERAL MOTORS CORP.
    5. Loosely install a rear bearing retainer bolt in the open hole. This is to hold the bearing retainer in place when the J 36515-10  is removed. See Special Tools .
  6. Remove the J 36515-10  . See Special Tools .
    7. NOTE: Refer to FASTENER NOTICE .
    Fig 5: Installing Mainshaft Rear Bearing Retaining Bolts
    GM4797Courtesy of GENERAL MOTORS CORP.
  7. Install the 3 mainshaft rear bearing retainer bolts.

    Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolt threads.

    Tighten:  Tighten the mainshaft rear bearing retainer bolts to 22 N.m (16 lb ft).

  8. Lay the housing assembly down on a work bench.
  9. Remove the rear housing assembly from the J 36515  , the J 36515-15  , and the J 36515-16  . See Special Tools .
    Fig 6: Removing Rear Housing Assembly From J 36515, J 36515-15 & J 36515-16
    GM4759Courtesy of GENERAL MOTORS CORP.
  10. Install the reverse idler shaft support.
    Fig 7: Installing Reverse Idler Shaft Support & Bolts
    GM4760Courtesy of GENERAL MOTORS CORP.
  11. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the reverse idler shaft bolt threads.
  12. Line up the bolt threads in the idler shaft support with the bolt hole.
  13. Install the reverse idler shaft bolts.
  14. Hold the reverse idler gear shaft against the idler support while tightening the bolts.

    Tighten:  Tighten the reverse idler gear shaft bolt to 22 N.m (16 lb ft).

  15. Install the 3rd/4th speed gear shift fork onto the 3rd/4th speed gear synchronizer sleeve.
    Fig 8: Installing 3rd/4th Gear Shift Fork
    GM4795Courtesy of GENERAL MOTORS CORP.
  16. Slide the shift shaft through the following parts:
    1. The 3rd/4th speed gear shift fork

      Ensure that the detent reliefs in the shift shaft point to the front of the transmission.

    2. The shift lever
    3. The block-out bushing
    4. The 1st/2nd speed gear shift fork
    5. The 5th/Reverse shift fork
    6. The rear case bushing and bearing
    7. The shift socket
    Fig 9: Installing Shift Shaft Through Components
    GM761062Courtesy of GENERAL MOTORS CORP.
  17. Install a new short roll pin into the shift lever. The end of the spiral must face toward the direction of the thrust.
    Fig 10: Installing Short Roll Pin
    GM4790Courtesy of GENERAL MOTORS CORP.
    1. Rotate the shift shaft and the shift lever/block-out bushing assembly. Ensure the roll pin holes are aligned and horizontal.
    2. Support the shift shaft while installing the roll pin.
    3. Install the roll pin flush with the shift lever.
    18. IMPORTANT: C/K trucks have 2 holes on the shift shaft. Use the front roll pin hole (1).
    Fig 11: Installing Shift Shaft
    GM4763Courtesy of GENERAL MOTORS CORP.
  18. Install the shift shaft, the shift shaft socket and the new long roll pin.
    1. Align the holes in the shift shaft socket and the shift shaft.
    2. Drive the roll pin flush with the bottom of the shift shaft socket.
  19. Install the detent spring and the ball plunger into the hole in the shift lever.
    1. Rotate the shift shaft counterclockwise. The shift lever should be almost into the 5th/Reverse speed gear insert notch.
    2. Install the spring (1) and the ball plunger (2) into the shift lever.
      Fig 12: Installing Shift Lever Spring & Ball Plunger
      GM4762Courtesy of GENERAL MOTORS CORP.
    3. Rotate the shift shaft until the shift lever aligns with the 3rd/4th speed gear insert.
    20. IMPORTANT: The transmission must remain in 3rd or 5th gear in order to prevent losing the shift shaft lever spring and plunger.
  20. Shift the transmission into 3rd or 5th gear.
    21. IMPORTANT: The smaller diameter of the bearing cage goes into the bearing race.
    Fig 13: Installing Countershaft Bearing
    GM548137Courtesy of GENERAL MOTORS CORP.
  21. Install the countershaft bearing onto the counter shaft.

    Ensure the smaller diameter side of the bearing is positioned toward the front case half.

  22. Fill the front countershaft bearing race with J 36850  or equivalent.
  23. Apply gasket maker GM P/N 1052943 (Canadian P/N 10953491) or equivalent to the front housing sealing surface.
  24. Align the dowel pins in the clutch housing to the rear case.
  25. Install the clutch housing to the rear case.
    Fig 14: Installing Clutch Housing
    GM548133Courtesy of GENERAL MOTORS CORP.
  26. Install the housing bolts.
    Fig 15: Installing Clutch Housing-To-Rear Case Bolts
    GM548129Courtesy of GENERAL MOTORS CORP.

    Do not tighten the bolts.

    27. IMPORTANT: Do not scratch the sealing surface on the input shaft while installing the retaining ring. Minor scratches may cause premature seal failure.
    Fig 16: Installing Input Shaft Retainer Ring
    GM548183Courtesy of GENERAL MOTORS CORP.
  27. Install a new retaining ring on the input shaft. It may be necessary to pull out on the input shaft in order to install the retaining ring.
    28. IMPORTANT: Do not allow sealant into the oil return hole in the housing or bearing retainer.
    Fig 17: Applying RTV Sealer To Retainer Mating Surface
    GM4770Courtesy of GENERAL MOTORS CORP.
  28. Apply RTV sealer GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the inside edge of the bearing retainer mating surface.
  29. Install the input shaft bearing retainer to the housing with 6 bolts.
    Fig 18: Installing Input Shaft Bearing Retainer Bolts
    GM761058Courtesy of GENERAL MOTORS CORP.

    Align the retainer oil drain hole with the drain hole in the housing.

    Tighten:  Tighten the retainer bolts to 14 N.m (10 lb ft).

  30. Rotate the input shaft a few turns to align the transmission bearings and to test for any excessive binding.
  31. Tighten the front to rear housing bolts.

    Tighten:  Tighten the housing bolts to 35 N.m (26 lb ft).

  32. Install the following components:
    1. The shift shaft detent plunger
    2. The shift shaft detent spring
    3. The shift shaft detent plug
      Fig 19: Installing Shift Shaft Detent Plunger, Spring & Plug
      GM548126Courtesy of GENERAL MOTORS CORP.

      Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the detent plug.

  33. If 2WD vehicle, coat the speed sensor O-ring with Synchromesh Transmission Fluid GM P/N 12345349 (Canadian P/N 10953465) or equivalent.
  34. Install the speed sensor, O-ring, and bolt.
    Fig 20: Installing Speed Sensor (2WD)
    GM761051Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the bolt to 16 N.m (12 lb ft).

  35. Install the backup lamp switch.
    Fig 21: Installing Back-Up Lamp Switch
    GM761049Courtesy of GENERAL MOTORS CORP.

    Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the backup lamp switch.

    Tighten:  Tighten the switch to 37 N.m (27 lb ft).

  36. Install the shift shaft detent pin.
    Fig 22: Installing Shift Shaft Detent Pin
    GM761053Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the detent pin to 25 N.m (18 lb ft).

  37. If C truck, using the J 36503  , install the output shaft seal. See Special Tools .
    Fig 23: Installing New Rear Oil Seal (2WD)
    GM548114Courtesy of GENERAL MOTORS CORP.
  38. If 4WD vehicle, install the J 36502-2A  on the output shaft. See Special Tools .
    Fig 24: Install New Output Shaft Seal (4WD)
    GM4758Courtesy of GENERAL MOTORS CORP.
  39. Install the output shaft seal using the J 36502  . See Special Tools .
  40. Remove the J 36502-2A  from the output shaft. See Special Tools .
  41. Fill the space between the seal lips with chassis grease.
    Fig 25: Applying Chassis Grease Between Seal Lips
    GM1420Courtesy of GENERAL MOTORS CORP.
  42. To prevent the transmission fluid from spilling while installing the transmission into the vehicle, fill the transmission after installing with Synchromesh Transmission Fluid GM P/N 12345349 (Canadian P/N 10953465) or equivalent.
scientia non olet · About LEMON Manuals