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Home >> Chevrolet >> 2006 >> Silverado 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 54 (Manual Transmission - ZF S6-650 - Overhaul) >> Repair Instructions >> Mainshaft Assemble

Mainshaft Assemble

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Tools Required

    NOTE: Refer to HEATING TRANSMISSION COMPONENT NOTICE in Cautions and Notices.
    IMPORTANT: Certain transmission components require preheating to 150°C (300°F). In order to preheat the components, use an electric oven. It is recommended to purchase a roaster/oven style locally. The oven should have a temperature setting thermostat.
  1. Preheat the following components for 30 minutes to 150°C (300°F) in an electric oven:
    • The mainshaft intermediate case bearing
    • The 2nd/3rd gear synchronizer hub
    • The 3rd speed gear bushing
    • The 4th gear thrust washer
    • The 4th speed gear bushing
    • The 4th/5th synchronizer hub
    • The mainshaft front bearing
    2. CAUTION: Refer to HANDLING PREHEATED PARTS CAUTION in Cautions and Notices.
  2. Position the mainshaft with the output end up in the J 44725  . See Special Tools .
  3. Wearing protective gloves, install the preheated mainshaft intermediate case bearing on the mainshaft. Rotate the bearing while installing, in order to seat it fully and squarely.
    Fig 1: Installing Mainshaft Intermediate Case Bearing On Mainshaft
    GM723285Courtesy of GENERAL MOTORS CORP.
  4. Turn the mainshaft over 180 degrees in the J 44725  , with the input end facing up. See Special Tools .
  5. Install the 2nd speed gear bearing on the mainshaft.
    Fig 2: Installing 2nd Gear & Bearing
    GM723292Courtesy of GENERAL MOTORS CORP.
  6. Lightly lubricate the bearing with GM P/N 12378515 (Canadian P/N 88900701).
  7. Install the 2nd speed gear on the mainshaft.
  8. Install the 2nd speed gear synchronizer inner ring. Align the tabs on the ring with the slots in the 2nd gear.
    Fig 3: Installing 2nd Gear Synchronizer Rings
    GM723296Courtesy of GENERAL MOTORS CORP.
  9. Install the 2nd speed gear synchronizer middle ring. Align the tabs in the 2nd gear.
  10. Install the 2nd speed gear synchronizer blocking ring.
  11. Ensure the 3 tabs of the synchronizer inner ring are aligned with the synchronizer blocking ring tabs.
  12. Lightly lubricate the synchronizer components with GM P/N 12378515 (Canadian P/N 88900701).
  13. Position the J 44725  (2) on a hydraulic press. See Special Tools . The J 44725  will be used to assemble the mainshaft while in a hydraulic press. See Special Tools .
    Fig 4: View Of J 44734 & J 44725
    GM723302Courtesy of GENERAL MOTORS CORP.
  14. Position the mainshaft on the J 44725  (2) with the input facing up. See Special Tools .
  15. Position the J 44734  (1) on the end of the mainshaft. See Special Tools . Using J 44734  will prevent the heated parts from getting caught on the mainshaft during installation. See Special Tools .
    16. CAUTION: Refer to HANDLING PREHEATED PARTS CAUTION in Cautions and Notices.
    Fig 5: Seating 2nd/3rd Gear Synchronizer Hub
    GM723307Courtesy of GENERAL MOTORS CORP.
  16. Wearing protective gloves, install the preheated 2nd/3rd gear synchronizer hub on the mainshaft. Position the hub with the part number facing up.
  17. Align the tabs on the 2nd gear synchronizer rings with the slots in 2nd/3rd gear synchronizer hub while installing the hub.
  18. Use the J 44735  (1) and a hydraulic press to fully seat the 2nd/3rd gear synchronizer hub. See Special Tools .
  19. Perform the following in order to ensure the 2nd gear synchronizer rings are properly installed in the 2nd/3rd gear synchronizer hub:
    Fig 6: Ensuring Proper Seating Of 2nd Gear Synchronizer Rings
    GM723311Courtesy of GENERAL MOTORS CORP.
    1. Rotate the 2nd speed gear back and forth.
    2. Looking through the slot in the hub, watch for movement of the blocking ring.
    3. The blocking ring should move approximately 2 mm (1/16 in).
  20. Using the J 26900-12  or the J 29763  with the J 26900-13  , measure the 2nd gear axial clearance. Clearance should be 0.15-0.35 mm (0.0059-0.0138 in).
    Fig 7: Measuring 2nd Gear Axial Clearance
    GM742111Courtesy of GENERAL MOTORS CORP.
    1. Position the J 26900-12  or the J 29763  on the top of the gear teeth. See Special Tools .
    2. Zero the gage.
    3. Lift up on the gear to measure the clearance.
  21. If clearance is higher than the specification, inspect to ensure the 2nd/3rd synchronizer hub is installed completely.
  22. If clearance is higher than the specification, inspect the 2nd speed gear, mainshaft, or 2nd/3rd synchronizer hub for wear.
  23. If clearance is lower than the specification, inspect the 2nd speed gear, mainshaft, or 2nd/3rd synchronizer hub for burrs.
  24. Repair or replace the damaged or worn component.
  25. Install the 2nd/3rd gear synchronizer sleeve.
    Fig 8: Installing 2nd/3rd Gear Synchronizer Sleeve
    GM723313Courtesy of GENERAL MOTORS CORP.
    • Position the sleeve part number side up.
    • Align the flat areas, square teeth, on the sleeve with the slots for the detent springs.
  26. Install the 2nd/3rd gear detent springs, pressure pieces, and balls in the synchronizer hub.
    Fig 9: Installing 2nd/3rd Gear Detent Springs, Pressure Pieces & Balls
    GM723314Courtesy of GENERAL MOTORS CORP.

    The 2nd/3rd synchronizer springs are 19.7 mm (0.775 in) long.

    1. Install all three springs and pressure pieces.
    2. Install the balls.
      3. IMPORTANT: If the 3rd gear synchronizer blocking ring is not installed before moving the sleeve to lock the balls in position, the springs will jump out of position.
    3. Install the 3rd gear synchronizer blocking ring to hold the balls and sleeve in the neutral position. The tabs on the blocking ring align with the slots in the hub without the detent pieces.
    4. Pull up on the sleeve to lock the balls in position.
  27. Install the 3rd gear synchronizer middle ring.
    Fig 10: Installing 3rd Gear Synchronizer Rings
    GM723319Courtesy of GENERAL MOTORS CORP.
  28. Install the 3rd gear synchronizer inner ring.
  29. Align the 3 tabs of the inner ring with the synchronizer hub slots.
  30. Lightly lubricate the synchronizer components with GM P/N 12378515 (Canadian P/N 88900701).
    31. CAUTION: Refer to HANDLING PREHEATED PARTS CAUTION in Cautions and Notices.
    Fig 11: Installing 3rd Gear Bushing
    GM723322Courtesy of GENERAL MOTORS CORP.
  31. Wearing protective gloves, install the preheated 3rd speed gear bushing.
  32. Use the J 44735  and a hydraulic press to fully seat the bushing. See Special Tools .
  33. Allow the 3rd speed gear bushing to cool.
  34. Install the 3rd speed gear bearing on the mainshaft.
  35. Lightly lubricate the bearing with GM P/N 12378515 (Canadian P/N 88900701).
  36. Install the 3rd speed gear.
    Fig 12: Installing 3rd Gear
    GM723323Courtesy of GENERAL MOTORS CORP.
  37. Align the 3rd gear synchronizer middle ring tabs with the holes in the 3rd speed gear.
    38. CAUTION: Refer to HANDLING PREHEATED PARTS CAUTION in Cautions and Notices.
  38. Wearing protective gloves, install the preheated 4th gear thrust washer on the mainshaft.
  39. Using the J 44735  and a hydraulic press, fully seat the thrust washer. See Special Tools .
    Fig 13: Seating Thrust Washer
    GM742287Courtesy of GENERAL MOTORS CORP.
  40. Allow the 4th gear thrust washer to cool.
  41. Using the J 26900-12  or the J 29763  with the J 26900-13  , measure the 3rd gear axial clearance. Clearance should be 0.15-0.35 mm (0.0059-0.0138 in).
    Fig 14: Measuring 3rd Gear Axial Clearance
    GM742112Courtesy of GENERAL MOTORS CORP.
    1. Position the J 26900-12  or the J 29763  on the top of the gear teeth. See Special Tools .
    2. Zero the gage.
    3. Lift up on the gear to measure the clearance.
  42. If clearance is higher than the specification, inspect to ensure the 4th gear thrust washer is installed completely.
  43. If clearance is higher than the specification, inspect the 3rd speed gear, the 4th gear thrust washer, or 2nd/3rd synchronizer hub for wear.
  44. If clearance is lower than the specification, inspect the 3rd speed gear, the 4th gear thrust washer, or 2nd/3rd synchronizer hub for burrs.
  45. Repair or replace the damaged or worn component.
    46. CAUTION: Refer to HANDLING PREHEATED PARTS CAUTION in Cautions and Notices.
  46. Wearing protective gloves, install the preheated 4th speed gear bushing on the mainshaft.
  47. Use the J 44735  and a hydraulic press to fully seat the bushing. See Special Tools .
    Fig 15: Installing 4th Gear Bushing
    GM723326Courtesy of GENERAL MOTORS CORP.
  48. Allow the 4th speed gear bushing to cool.
  49. Install the 4th speed gear bearing.
    Fig 16: Installing 4th Gear Bearing
    GM662028Courtesy of GENERAL MOTORS CORP.
  50. Lightly lubricate the bearing with GM P/N 12378515 (Canadian P/N 88900701).
  51. Install the 4th speed gear on the mainshaft.
  52. Install the 4th speed gear synchronizer ring.
    Fig 17: Installing 4th Gear Synchronizer Rings
    GM723808Courtesy of GENERAL MOTORS CORP.
  53. Lightly lubricate the synchronizer components with GM P/N 12378515 (Canadian P/N 88900701).
    54. CAUTION: Refer to HANDLING PREHEATED PARTS CAUTION in Cautions and Notices.
    Fig 18: Installing 4th/5th Synchronizer Hub
    GM723813Courtesy of GENERAL MOTORS CORP.
  54. Wearing protective gloves, install the preheated 4th/5th synchronizer hub on the mainshaft.
    • Install the hub with the part number facing up.
    • Align the tabs on the synchronizer ring with the slots in the hub.
  55. Use the J 44735  and a hydraulic press to fully seat the synchronizer hub. See Special Tools .
    Fig 19: Seating 4th/5th Synchronizer Hub
    GM742303Courtesy of GENERAL MOTORS CORP.
  56. Install the retaining ring for the 4th/5th gear synchronizer hub.
    Fig 20: Installing 4th/5th Synchronizer Hub Retaining Ring
    GM662025Courtesy of GENERAL MOTORS CORP.
    • The retaining rings are different thicknesses.
    • Select a retaining ring that fills the groove.
    • Ensure the retaining ring is fully seated.
  57. Using the J 26900-12  or the J 29763  with the J 26900-13  , measure the 4th gear axial clearance. Clearance should be 0.15-0.35 mm (0.0059-0.0138 in).
    Fig 21: Measuring 4th Gear Axial Clearance
    GM742113Courtesy of GENERAL MOTORS CORP.
    1. Position the J 26900-12  or the J 29763  on the top of the gear teeth. See Special Tools .
    2. Zero the gage.
    3. Lift up on the gear to measure the clearance.
  58. If clearance is higher than the specification, inspect to ensure the 4th/5th gear synchronizer hub is installed completely.
  59. If clearance is higher than the specification, inspect the 4th speed gear, the 4th gear thrust washer, or 4th/5th synchronizer hub for wear.
  60. If clearance is lower than the specification, inspect the 4th speed gear, the 4th gear thrust washer, or 4th/5th synchronizer hub for burrs.
  61. Repair or replace the damaged or worn component.
    62. CAUTION: Refer to HANDLING PREHEATED PARTS CAUTION in Cautions and Notices.
    Fig 22: Installing Mainshaft Front Bearing
    GM723818Courtesy of GENERAL MOTORS CORP.
  62. Wearing protective gloves, install the preheated mainshaft front bearing on the mainshaft using the J 44734  and hydraulic press. See Special Tools .
    • Turn the J 44734  over to use it to press on the bearing. See Special Tools .
    • Do not use a hammer on the J 44734  . See Special Tools . Damaging the J 44734  may prevent further use of the tool for transmission assembly. See Special Tools .
  63. Install the 4th/5th speed gear synchronizer sleeve. Align the sleeve with the part number facing up.
    Fig 23: Installing 4th/5th Gear Synchronizer Sleeve
    GM723823Courtesy of GENERAL MOTORS CORP.
  64. Install the 4th/5th speed gear detent springs, and pressure pieces in the synchronizer hub.
    Fig 24: Installing Synchronizer Components
    GM724270Courtesy of GENERAL MOTORS CORP.

    The 4th/5th synchronizer springs are 22.7 mm (0.893 inch) long.

    1. Install all 3 springs and pressure pieces.
      2. IMPORTANT: In order to prevent the springs and balls from jumping out of position, install the 5th gear synchronizer blocking ring. Move the sleeve to lock the sleeve in position.
    2. Install the 5th gear synchronizer ring to hold the pressure pieces and the sleeve in position.
    3. Pull up on the sleeve to lock the pressure pieces in the neutral position.
  65. Fill the input shaft front mainshaft bearing race with J 36850  or equivalent.
  66. Install the input shaft.
    Fig 25: Installing Input Shaft
    GM662023Courtesy of GENERAL MOTORS CORP.
  67. Move the 4th/5th synchronizer sleeve to the 5th gear position. Locking the mainshaft to the input shaft prevents the synchronizer from falling apart.
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