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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1159 (Manual Transmission - AISIN AY6) >> Repair Instructions - Off Vehicle >> Shift Shaft and Shift Fork Cleaning and Inspection >> Notes

Shift Shaft and Shift Fork Cleaning and Inspection: Notes

WARNING: This page is about a different car, the 2008 Cadillac CTS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Shift Control Shaft, Shift Shaft Detent & Components
    GM1480404Courtesy of GENERAL MOTORS CORP.
  1. Using a suitable punch and hammer, remove the pin (100) from the dynamic damper weight (101).
  2. Remove the shift shaft detent cam (45) and the weight (101) from the shift control shaft (66).
  3. Remove the shift shaft detent (67) and the shift shaft detent spring (74).
  4. Remove the bolt (76) from the shift shaft detent lever (62).
  5. Remove the shift shaft detent lever (62) from the shift control shaft (66).
    6. Fig 2: View Of 1st/2nd Shift Shaft & Components
    GM1480405Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The shift detent ball (80) and spring (73) will come out of the shift control lever when the 1st/2nd shift shaft (58) is removed.
  6. Remove the 1st/2nd shift fork pin (70).
  7. Remove the 1st/2nd shift shaft (58).
  8. Remove the slotted pin (70) from the select control lever assembly (57). Slide the select control lever assembly (57) from the 1st/2nd shift shaft (58).
  9. Using a suitable punch and hammer, remove the pin (78) from the shift control lever bracket (44).
    10. Fig 3: View Of 3rd/4th Shift Shaft & Components
    GM1480409Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The shift detent ball (80) and spring (73) will come out of the shift control lever bracket (44) when the 3rd/4th shift shaft (59) is removed.
  10. Remove the bolt (69) from the 3rd/4th shift fork (49).
  11. Remove the 3rd/4th shift shaft (59).
  12. Remove the shift fork (49).
  13. Use a magnet to remove pins (77 and 78).
    14. Fig 4: View Of 5th/6th Shift Shaft & Components
    GM1480407Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The shift detent ball (80) and spring (73) will come out of the shift control lever bracket (44) when the 5th/6th shift shaft (60) is removed.
  14. Remove the bolt (69) from the 5th/6th shift fork (52). Slide the 5th/6th shift fork (52) from the 5th/6th shift shaft (60).
  15. Remove the 5th/6th shift shaft (60).
  16. Using a suitable punch and hammer, remove the pin (70) from the shift lever assembly (55). Slide the shift lever assembly (55) from the 5th/6th shift shaft (60).
  17. Using a suitable punch and hammer, remove pins (77 and 72).
    18. Fig 5: View Of 1st/2nd Shift Fork Assembly, Reverse Shift Shaft & Components
    GM1480412Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The shift detent ball (80) and spring (73) will come out of the shift control lever bracket (44) when the reverse shift shaft (61) is removed.
  18. Using a suitable punch and hammer, remove the slotted pin (71) from the reverse shift fork (63). Slide the reverse shift fork (63) off the reverse shift shaft (61).
  19. Remove the reverse shift shaft assembly.
  20. Using a suitable punch and hammer, remove the long, slotted pin (70) from the internal shift control lever (56). Slide the internal shift control lever (56) and 1st/2nd shift fork assembly (46) from the reverse shift shaft (61).
    21. Fig 6: View Of Control Select Arm Pin, Shift Control Lever Bracket & E-Ring
    GM1480415Courtesy of GENERAL MOTORS CORP.
  21. Remove the E-ring (82) and pull the control select arm pin (51) from the shift control lever bracket (44).
  22. Remove the control select arm (50) from the shift control lever bracket (44).
    23. Fig 7: Inspecting Cam, Shift Forks & Assembly
    GM1485535Courtesy of GENERAL MOTORS CORP.
  23. Inspect the cam (45), shift forks (49), (52), (63) and assembly (46) for:
    • Bent fork
    • Hole for wear
    • Cracks
    24. Fig 8: Measuring Fork Width & Sleeve Groove Width
    GM1527255Courtesy of GENERAL MOTORS CORP.
  24. Measure the fork width and sleeve groove width for wear. If synchronizer sleeve to shift fork width clearance exceeds the maximum, replace the synchronizer sleeve and/or shift fork. Refer to Transmission Clearance Specifications  and see Synchronizer Sleeve to Shift Fork - Maximum Clearance  table.
    25. Fig 9: Inspecting Detent Lever, Assembly, Shift Shaft & Control Lever
    GM1485544Courtesy of GENERAL MOTORS CORP.
  25. Inspect the detent lever (62), assembly (56 and 57), shift shaft (59) and control lever (56) for:
    • Bent fork
    • Hole for wear
    • Cracks
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