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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 58 (Manual Transmission - ZF S6-650 - Overhaul) >> Repair Instructions >> Shift Shaft and Shift Forks Cleaning and Inspection

Shift Shaft and Shift Forks Cleaning and Inspection

WARNING: This page is about a different variant/trim than selected.
  1. Clean all the parts in a suitable cleaning solvent and air dry.
  2. Roll the shift shafts on a flat surface to inspect them for being bent.
  3. Inspect the shift shafts for wear or scoring.
    Fig 1: Inspecting Shift Shafts
    GM741981Courtesy of GENERAL MOTORS CORP.
  4. If light scoring, dress the area using a soft stone. Do not use a file.
  5. Inspect the roll pin locations (1) for flaring or damage.
  6. If damaged, dress the roll pin locations (1) using a soft stone. Do not use a file.
  7. Inspect the shift shaft detent notches (3) for excessive rounding or distortion.
  8. Inspect the shift shaft internal shift control lever notches (2) for damage or wear.
  9. Replace the shift shaft if damaged or excessively worn.
  10. Inspect the shift shaft forks for wear through the harden surface, scoring, or distortion.
    Fig 2: Inspecting Shift Shaft Forks
    GM741982Courtesy of GENERAL MOTORS CORP.
  11. Inspect for a bent shift fork.
  12. Replace the shift forks if damaged or excessively worn.
  13. Inspect the shift shaft detent springs for distortion.
  14. Inspect the internal shift control levers (2 and 4) for wear or damage.
    Fig 3: Inspecting Shift Interlock Plate, Shift Shaft Block & Internal Shift Control Levers
    GM741984Courtesy of GENERAL MOTORS CORP.
  15. Inspect the shift interlock plate (1) for damage or wear.
    • Inspect shift block teeth area.
    • Inspect mounting bolt slots.
    • Inspect for being bent or warped.
  16. Inspect the shift shaft block (3) for excessively worn teeth.
  17. Replace any damaged or excessively worn parts.
    18. IMPORTANT: When removing the roll pins from the shift shafts, use a punch that is a slightly smaller diameter than the roll pin. Flaring of the shift shaft groove may occur if the punch binds. This will result in extra effort to remove the shift forks or shift control levers. When double roll pins are used, remove both of the roll pins at the same time. Back-up the component when removing the roll pins to prevent damage to the shift shafts. Do not use the roll pins again after removal.
  18. If the 4th/5th shift fork or shift shaft requires replacement, remove both roll pins.
  19. Remove the shift fork from the shift shaft.
  20. Install the shift fork on the shift shaft.
  21. Install the NEW roll pins in the 4th/5th shift fork.
    Fig 4: Installing Shift Shaft & Roll Pins To Shift Shaft Fork - 4th/5th Gear
    GM661998Courtesy of GENERAL MOTORS CORP.
    1. Install the large diameter roll pin.
    2. Align the split on the roll pin away from the transmission side of the shift fork.
    3. Install the small diameter roll pin inside of the large diameter roll pin.
    4. Align the split on the roll pin toward the transmission side of the shift fork.
  22. If the 2nd/3rd shift fork or shift shaft requires replacement, remove both roll pins.
  23. Remove the shift fork from the shift shaft.
  24. Install the shift fork on the shift shaft.
  25. Install the NEW roll pins in the 2nd/3rd shift fork.
    Fig 5: Installing Shift Shaft & Roll Pins To Shift Shaft Fork - 2nd/3rd Gear
    GM662002Courtesy of GENERAL MOTORS CORP.
    1. Install the large diameter roll pin.
    2. Align the split on the roll pin away from the transmission side of the shift fork.
    3. Install the small diameter roll pin inside of the large diameter roll pin.
    4. Align the split on the roll pin toward the transmission side of the shift fork.
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