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Shift System Components

WARNING: This page is about a different car, the 2007 GMC Sierra and 2007 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Shift System Components
    GM1578750Courtesy of GENERAL MOTORS CORP.
  1. Clean the following shift system components in cleaning solvent and air dry:
    • The high/low shift fork (1)
    • The range sleeve (2)
    • The 2/4 wheel drive mode shift fork (3)
    • The shift fork shaft (4)
    • The control actuator lever shaft (5)
    • The synchronizer assembly (6)
  2. Inspect the shift fork shaft for straightness (4).
  3. Replace the shift fork shaft if it is not straight.
    4. Fig 2: View Of High/Low Shift Fork Inspection Areas
    GM887087Courtesy of GENERAL MOTORS CORP.
  4. Inspect the pads (1) on the high/low shift fork for wear.
  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. Fig 3: Identifying Inspection Areas On Two/Four Wheel Drive Mode Shift Fork
    GM812479Courtesy of GENERAL MOTORS CORP.
  7. Inspect the 2/4 wheel drive mode shift fork roller (1) for the following conditions:
    • Wear
    • Rotates easily
  8. Inspect the shift fork for worn wear pads (3).
  9. Inspect the shift fork bearing (2) for being faulty.
  10. Replace the shift fork if the above conditions are found.
    11. Fig 4: View Of Inspection Areas On Range Sleeve
    GM801271Courtesy of GENERAL MOTORS CORP.
  11. Inspect the range sleeve for chipped or excessive worn teeth (1).
  12. Inspect the shift fork collar (2) on the range sleeve for wear.
  13. Inspect the inner splines (3) of the range sleeve for excessive looseness on the rear output shaft.
  14. Replace the range sleeve if the above conditions are found.
    15. Fig 5: Locating Inspection Areas On Sector Shaft
    GM812485Courtesy of GENERAL MOTORS CORP.
  15. Inspect the high/low shift fork roller slot (2) on the control actuator lever shaft for wear or roughness.
  16. Inspect the bearing (1) and the seal surface on the control actuator lever shaft for the following conditions:
    • Pitted
    • Wear
    • Corrosion
  17. Inspect the 2/4 wheel drive mode shift fork cam lobes (3) on the control actuator lever shaft for wear or roughness.
  18. Inspect the detent plunger cam lobes (4) for wear or roughness.
  19. Replace the control actuator lever shaft if any of the above conditions are found.
    20. Fig 6: Exploded View Of Synchronizer Assembly
    GM812463Courtesy of GENERAL MOTORS CORP.
  20. Inspect the inner synchronizer ring (1) for wear and roughness.
  21. Inspect the middle synchronizer ring (2) friction material for wear or damage.
  22. Inspect the outer synchronizer ring (3) for wear.
  23. Inspect the synchronizer sleeve (4) for the following conditions:
    • Wear on the engagement teeth
    • Wear in the insert notches
  24. 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)
  25. Replace the synchronizer assembly if any of the above parts are faulty.
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