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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 >> Transmission Assemble

Transmission Assemble

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

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.
    • Lubricate all bearings, shafts, and synchronizers with transmission fluid GM P/N 12378515 (Canadian P/N 88900701) during installation.
    Fig 1: Identifying Main & Countershaft Assemblies
    GM662020Courtesy of GENERAL MOTORS CORP.
  1. Preheat the following components for 30 minutes to 150°C (300°F) in an electric oven:
    • The 6th gear bearing bushing
    • The reverse gear bearing bushing
    • The reverse gear thrust washer
    • The mainshaft rear bearing
  2. Turn the mainshaft assembly over 180 degrees so that the input shaft is on the J 44725  . See Special Tools . Hold the input shaft to the mainshaft while turning over.
  3. Position the countershaft on the J 44725  . See Special Tools .

    Roll the countershaft into place to merger the countershaft and mainshaft gears.

  4. Install the spacer for the 6th speed gear synchronizer hub on the countershaft.
    Fig 2: Installing 6th Gear Spacer
    GM724133Courtesy of GENERAL MOTORS CORP.
  5. Assemble the 2nd/3rd shift fork and shift shaft and the 4th/5th shift fork and shift shaft in the interlock plate.
    Fig 3: Assembling 2nd/3rd & 4th/5th Shift Forks & Shafts
    GM663680Courtesy of GENERAL MOTORS CORP.
    • The part number end of the shift shafts goes up.
    • The part number side of the interlock plate goes down.
  6. Install the 2nd/3rd shift fork and the 4th/5th shift fork in the synchronizer sleeves.
  7. Install the intermediate case over the countershaft, the mainshaft, 2nd/3rd shift shaft, and the 4th/5th shift shaft.
    Fig 4: Installing Intermediate Case
    GM662019Courtesy of GENERAL MOTORS CORP.
    • Align the shift shafts straight with the shift shaft bearings.
    • Wiggle the intermediate case over the shift shafts while installing.
  8. Install the shift interlock plate to the intermediate case. The part number side faces away from the intermediate case.
    Fig 5: Installing Shift Interlock Plate
    GM663713Courtesy of GENERAL MOTORS CORP.
    9. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  9. Install the interlock plate bolts. Ensure the shoulder of the bolts do not catch on the plate.

    Tighten:  Tighten the interlock plate bolts to 10 N.m (88 lb in).

  10. Ensure the interlock plate moves freely.
  11. Install the retaining ring in the 6th speed gear synchronizer hub, if removed.
  12. Install the 6th speed gear synchronizer hub on the countershaft.
    Fig 6: Installing 6th Gear Synchronizer Hub
    GM724135Courtesy of GENERAL MOTORS CORP.
    • The hub side with the retaining ring goes toward the intermediate case.
    • The hub should slide on the countershaft.
  13. If not already assembled, assemble the 6th gear synchronizer assembly.
    Fig 7: Assembling 6th Gear Synchronizer Components
    GM740023Courtesy of GENERAL MOTORS CORP.

    The 6th gear synchronizer springs are 22.7 mm (0.893 in) long.

    1. Install all three springs and the pressure pieces in the synchronizer sleeve.
    2. Install the 6th gear synchronizer sleeve on the hub. The part numbered side goes up.
      3. IMPORTANT: In order to prevent the springs and pressure pieces from jumping out of position, install the 6th gear synchronizer blocking ring. Move the sleeve to lock the pressure pieces in position.
    3. Install the 6th gear synchronizer blocking ring. Align the tabs on the blocking ring with the slots in the hub.
    4. Pull up on the sleeve to lock the pressure pieces in the neutral position.
    14. CAUTION: Refer to HANDLING PREHEATED PARTS CAUTION in Cautions and Notices.
    Fig 8: Installing 6th Gear Bushing
    GM724142Courtesy of GENERAL MOTORS CORP.
  14. Wearing protective gloves, install the preheated 6th gear bushing on the countershaft. Rotate the bushing while installing in order to seat them fully and squarely.
  15. Install the 6th speed gear bearing (3).
    Fig 9: Installing 6th Gear & Components
    GM662009Courtesy of GENERAL MOTORS CORP.
  16. Install the 6th speed gear (2).
  17. Install the 6th speed gear spacer washer (1).
  18. Lightly lubricate the components with GM P/N 12378515 (Canadian P/N 88900701).
  19. Install the 6th speed gear retaining ring.
    Fig 10: Installing 6th Gear Retaining Ring
    GM662008Courtesy of GENERAL MOTORS CORP.
    • The retaining rings are different thicknesses.
    • Select a retaining ring that fills the groove.
    • Retaining ring tabs should be under the gear teeth.
    • Ensure the retaining ring is fully seated.
  20. If the 1st/reverse synchronizer requires assembly, use the following procedure:
    Fig 11: Assembling 1st/Reverse Synchronizer Components
    GM724270Courtesy of GENERAL MOTORS CORP.
    1. Lightly lubricate the components with GM P/N 12378515 (Canadian P/N 88900701).
    2. With the oil grooves, or the part number side up, install the synchronizer hub on the 1st gear synchronizer blocking ring.
    3. With the synchronizer sleeve chamfer side down, install the sleeve on the hub.
    4. Install the synchronizer springs and pressure pieces.
    5. Install the reverse gear synchronizer blocking ring.
  21. Install the following components on the mainshaft:
    1. Lightly lubricate the bearings with GM P/N 12378515 (Canadian P/N 88900701).
    2. The 1st gear bearings
    3. The 1st speed gear
    4. The 1st/reverse gear synchronizer assembly with the hub part numbers facing up
      5. Fig 12: Installing 1st Gear & Synchronizer Assembly
      GM724148Courtesy of GENERAL MOTORS CORP.
    22. CAUTION: Refer to HANDLING PREHEATED PARTS CAUTION in Cautions and Notices.
    Fig 13: Installing Reverse Gear Bushing
    GM724149Courtesy of GENERAL MOTORS CORP.
  22. Wearing protective gloves, install the preheated reverse speed gear bushing on the mainshaft. Rotate the bushing while installing to ensure the bushing is fully and squarely seated.
  23. Install the reverse gear bearings.
  24. Lightly lubricate the bearings with GM P/N 12378515 (Canadian P/N 88900701).
  25. Install the reverse gear.
    Fig 14: Installing Reverse Gear
    GM724150Courtesy of GENERAL MOTORS CORP.
    26. CAUTION: Refer to Handling Preheated Parts Caution in Cautions and Notices.
  26. If RWD, wearing protective gloves, install the preheated thrust washer on the mainshaft.
  27. Use the J 44735  and a hammer to ensure the thrust washer is fully and squarely seated. See Special Tools .
    Fig 15: Installing Thrust Washer
    GM742362Courtesy of GENERAL MOTORS CORP.
    28. CAUTION: Refer to Handling Preheated Parts Caution in Cautions and Notices.
    IMPORTANT: The mainshaft rear bearing for a 4WD vehicle is a sealed bearing.
    Fig 16: Installing Mainshaft Rear Bearing
    GM724159Courtesy of GENERAL MOTORS CORP.
  28. Wearing protective gloves, install the preheated mainshaft rear bearing on the mainshaft. Rotate the bearing while installing to ensure the bearing is fully and squarely seated.
  29. If 4WD, install the retaining ring for the mainshaft rear bearing. Ensure the retaining ring is fully seated.
    Fig 17: Installing Mainshaft Rear Bearing Retaining Ring (4WD)
    GM722214Courtesy of GENERAL MOTORS CORP.
  30. If RWD, install the vehicle speed sensor reluctor wheel.
    Fig 18: Installing VSS Reluctor Wheel (RWD)
    GM724163Courtesy of GENERAL MOTORS CORP.

    The reluctor wheel should slide on the mainshaft.

  31. Install the 6th gear shift fork and rail.
    Fig 19: Installing 6th Gear Shift Fork & Rail
    GM662003Courtesy of GENERAL MOTORS CORP.
    1. The part numbered end goes up on the shift rail.
    2. Install the shift fork to the 6th gear synchronizer assembly.
    3. Move the shift interlock plate toward the 1st/reverse position if necessary.
    4. Tap the shift rail with a soft-face hammer into the shift fork and the intermediate case.
  32. Install the 1st/reverse shift fork and rail.
    Fig 20: Installing 1st/Reverse Shift Fork & Shaft
    GM662004Courtesy of GENERAL MOTORS CORP.
    1. The part numbered end goes up on the shift rail.
    2. Install the shift fork to the 1st/reverse gear synchronizer hub.
    3. Move the interlock plate toward 6th gear shift rail.
    4. Tap the shift rail with a soft-face hammer into the shift fork and the intermediate case.
  33. Install the NEW roll pins in the 6th gear shift fork (2). A roll pin goes in each hole.
    Fig 21: Installing 6th Gear & 1st/Reverse Gear Shift Fork Roll Pins
    GM663682Courtesy of GENERAL MOTORS CORP.
  34. Install the NEW roll pins in the 1st/reverse gear shift fork (1). A roll pin goes in each hole.
  35. If removed, install the shift block on the main shift rail.
    Fig 22: Installing Shift Block On Main Shift Rail
    GM724351Courtesy of GENERAL MOTORS CORP.
    1. The part numbers on the shift block and the part number on the shift rail face the same direction.
    2. Install the NEW large diameter roll pin.
    3. Install the NEW small diameter roll pin with the roll pin split 180 degrees from the large roll pin split.
  36. Install the front internal shift lever on the main shift rail.
    Fig 23: Installing Front Internal Shift Lever
    GM662001Courtesy of GENERAL MOTORS CORP.
    • Align the roll pin, or lever end, toward the part numbered end of the shift rail.
    • Do not install the roll pins.
  37. With the part numbered end pointing up, install the main shift rail.
  38. Align the shift block teeth on the main shift rail with the shift interlock plate.
    Fig 24: Aligning Shift Block Teeth With Shift Interlock Plate
    GM724177Courtesy of GENERAL MOTORS CORP.

    The center tooth on the shift block installs between the two teeth on the shift interlock plate.

  39. Position the front internal shift lever to align with the notch in the 2nd/3rd shift rail.
  40. Install the NEW roll pins in the internal shift control front lever.
    Fig 25: Installing Internal Shift Control Front Lever Roll Pin
    GM661262Courtesy of GENERAL MOTORS CORP.
    1. Install the large diameter roll pin.
    2. Align the split on the roll pin away from the transmission.
    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.
  41. Install the internal shift control rear lever on the main shift rail.
    Fig 26: Installing Internal Shift Control Rear Lever
    GM661975Courtesy of GENERAL MOTORS CORP.
  42. Align the levers on the internal shift control rear lever with the slots in the 1st/reverse gear shift rail and the 6th gear shift rail.
  43. Install the NEW roll pins in the internal shift control rear lever.
    Fig 27: Installing Internal Shift Control Rear Lever Roll Pin
    GM661258Courtesy of GENERAL MOTORS CORP.
    1. Install the large diameter roll pin.
    2. Align the split on the roll pin away from the transmission.
    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.
  44. Install the shift shaft detent plungers and springs.
    Fig 28: Installing Shift Shaft Detent Spring & Plunger
    GM661996Courtesy of GENERAL MOTORS CORP.
  45. Apply a thin layer of gasket maker GM P/N 12378517 (Canadian P/N 88900757) to the shift shaft detent caps.
  46. Using an 11 mm (27/64 in) punch, install the shift shaft detent caps.
  47. Shift the transmission into 5th gear in order to lock the input shaft to the mainshaft.
    Fig 29: Locking Input Shaft To Mainshaft
    GM662022Courtesy of GENERAL MOTORS CORP.
  48. Install S-hooks and a chain to the intermediate case.
    Fig 30: Installing S-Hooks & Chain To Intermediate Case
    GM661238Courtesy of GENERAL MOTORS CORP.
  49. Position the front of the front case on boards in order to allow the protrusion of the input shaft.
  50. Using a suitable lifting device, install the gear assembly to the front case.
    Fig 31: Installing Gear Assembly
    GM661239Courtesy of GENERAL MOTORS CORP.
    • Lower the gear assembly slowly in order to align the intermediate case dowel pins with the front case.
    • Do not use a sealer at this time.
    51. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
    Fig 32: Installing Intermediate Case Bolts
    GM661237Courtesy of GENERAL MOTORS CORP.
  51. Install the two intermediate to front case bolts.

    Tighten:  Tighten the intermediate case bolts to 23 N.m (17 lb ft).

  52. Assemble the J 44739  to the intermediate case, to measure the countershaft preload. See Special Tools .
    Fig 33: Installing J 44739 To Measure Countershaft Preload
    GM821070Courtesy of GENERAL MOTORS CORP.
    1. Install the crosspiece so that the 2 holes are closer to the single bolt hole upright in the lowest notch. Do not tighten the thumbscrew.
    2. Install the crosspiece to the 2 bolt hole upright in the lowest notch. Do not tighten the thumbscrew.
    3. Using a case bolt, install the single bolt hole upright to the 7th case bolt hole from the top, on the right side of the case.
    4. Using a case bolt in the hole away from the upright, install the 2 bolt hole upright to the 5th case bolt hole from the top, on the left side of the case.
    5. Tighten the crosspiece thumbscrews.
  53. Use the following procedure in order to measure the countershaft bearing clearance:
    1. Install the J 26900-12  or the J 29763  in the J 44739  . See Special Tools .
      Fig 34: Measuring Countershaft Bearing Clearance
      GM724197Courtesy of GENERAL MOTORS CORP.
    2. Adjust the J 26900-12  or the J 29763  to zero. See Special Tools .
    3. Using a suitable prying tool, lift up the countershaft.
    4. Record the dial indicator reading. This is the countershaft bearing clearance.
  54. Using the following formula, establish the shim thickness required for the countershaft bearing preload:
    1. Add the mainshaft preload specification 0.02-0.09 mm (0.0008-0.0035 in) to the countershaft bearing clearance measurement.
    2. The total is the shim thickness required under the countershaft bearing race in order to set the bearing preload.

      Example

      • 1.8 mm (0.070 in) mainshaft bearing clearance measurement
      • Plus 0.02-0.09 mm (0.0008-0.0035 in) countershaft preload specification
      • Equals 1.82-1.89 mm (0.070-0.074 in) shim thickness required
  55. Assemble the J 44739  to the intermediate case, to measure the mainshaft preload. See Special Tools .
    Fig 35: Installing J 44739 To Measure Mainshaft Preload
    GM821071Courtesy of GENERAL MOTORS CORP.
    1. Install the crosspiece so that the 2 holes are closer to the single bolt hole upright in the upper notch, for RWD, or center notch for 4WD. Do not tighten the thumbscrew.
    2. Install the crosspiece to the 2 bolt hole upright in the upper notch, for RWD, or center notch for 4WD. Do not tighten the thumbscrew.
    3. Using a case bolt, install the single bolt hole upright to the 3rd case bolt hole from the top, on the right side of the case.
    4. Using a case bolt in the hole closest to the upright, install the upright with the 2 bolt holes to the 6th case bolt hole from the top, on the left side of the case.
    5. Tighten the thumbscrews.
  56. Use the following procedure in order to measure the mainshaft bearing clearance.
    1. Install the J 26900-12  or the J 29763  in the J 44739  . See Special Tools .
    2. Adjust the J 26900-12  or the J 29763  to zero. See Special Tools .
      Fig 36: Measuring Mainshaft Bearing Clearance
      GM724199Courtesy of GENERAL MOTORS CORP.
    3. Using a suitable prying tool, lift the mainshaft up.
    4. Record the dial indicator reading. This is the mainshaft bearing clearance measurement.
  57. Using the following formula, establish the shim thickness required for the mainshaft bearing preload:
    1. Measure the input shaft bearing oil deflector thickness. Record this measurement.
    2. Subtract the oil deflector measurement from the mainshaft bearing clearance measurement.
    3. Add the mainshaft preload specification 0.02-0.09 mm (0.0008-0.0035 in).
    4. The total is the shim thickness required under the input bearing race in order to set the bearing preload.

      Example

      • 0.50 mm (0.020 in) oil deflector thickness
      • minus 2.2 mm (0.087 in) mainshaft bearing clearance measurement
      • equals 1.7 mm (0.067 in)
      • plus 0.02-0.09 mm (0.008-0.0035 in) mainshaft preload specification
      • equals 1.75 mm (0.069 in) shim thickness required
  58. Remove the 2 bolts retaining the intermediate case to the front case.
    Fig 37: Removing Intermediate Case Bolts
    GM661237Courtesy of GENERAL MOTORS CORP.
  59. Using S-hooks, a chain and a suitable lifting device, remove the gear assembly.
    Fig 38: Removing Gear Assembly
    GM661239Courtesy of GENERAL MOTORS CORP.
  60. Remove the mainshaft front bearing race using the J 44736  (1) and the J 44733  (2). See Special Tools .
    Fig 39: Removing Mainshaft Front Bearing Race
    GM722220Courtesy of GENERAL MOTORS CORP.
    1. Expand the J 44733  (2) to fit securely under the bearing race. See Special Tools .
    2. Align the legs of the J 44733  to rest on the webbing of the case. See Special Tools .
    3. Remove the mainshaft front bearing race.
  61. Remove the countershaft front bearing race using the J 44736  (1) and the J 44728  (2). See Special Tools .
    Fig 40: Removing Countershaft Front Bearing Race
    GM722224Courtesy of GENERAL MOTORS CORP.
    1. Install the J 44728  (2) in order for the fingers to fit in the notches in the case. See Special Tools .
    2. Expand the J 44728  (2) to fit securely in the bearing race. See Special Tools .
    3. Align the legs of the J 44736  to rest on the webbing of the case. See Special Tools .
    4. Remove the countershaft front bearing race.
  62. Using the J 25070  , heat the front case for 10-15 minutes.
    Fig 41: Heating Front Case
    GM722853Courtesy of GENERAL MOTORS CORP.
  63. Install the required shims for the countershaft bearing preload.
    Fig 42: Installing Countershaft Bearing Shim
    GM724204Courtesy of GENERAL MOTORS CORP.
    64. IMPORTANT: Install the bearing races with the front case still hot. Do not allow the front case to cool.
    Fig 43: Installing Countershaft Front Bearing Race
    GM722852Courtesy of GENERAL MOTORS CORP.
  64. Install the countershaft front bearing race using the J 8092  (1), J 21465-13  (2) and the J 44745  (3). See Special Tools .
  65. Install the oil trough.
    Fig 44: Installing Oil Trough
    GM722690Courtesy of GENERAL MOTORS CORP.
  66. Install the required shims for the mainshaft bearing preload.
  67. Install the input shaft gear oil deflector.
    Fig 45: Installing Input Gear Oil Deflector
    GM722688Courtesy of GENERAL MOTORS CORP.
  68. Install the mainshaft front bearing race using the J 8092  (1),J 21465-13  (2) and the. See Special Tools .J 44746  (3). See Special Tools .
    Fig 46: Installing Mainshaft Front Bearing Race
    GM722851Courtesy of GENERAL MOTORS CORP.
  69. Allow the front case to cool.
  70. Apply a thin layer of gasket maker GM P/N 12378517 (Canadian P/N 88900757) to the sealing surface of the front case.
  71. Using a suitable lifting device, install the gear assembly to the front case.
    Fig 47: Installing Gear Assembly
    GM661239Courtesy of GENERAL MOTORS CORP.
  72. Install the 2 intermediate case to front case bolts.
    Fig 48: Installing Intermediate Case Bolts
    GM661237Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the intermediate case bolts to 23 N.m (17 lb ft).

  73. Apply a thin layer of gasket maker GM P/N 12378517 (Canadian P/N 88900757) to the sealing surface of the rear case.
  74. Install the rear case on the intermediate case.
    Fig 49: Installing Rear Case Retaining Bolts
    GM661233Courtesy of GENERAL MOTORS CORP.
  75. Using a soft-face hammer, tap down on the rear case to seat it on the dowel pins. Do not use the bolts to draw the case together.
  76. Install the required brackets and the rear case bolts.

    Tighten:  Tighten the rear case bolts in a crossover sequence to 23 N.m (17 lb ft).

  77. Apply a thin layer of threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the threads of the shift shaft detent sleeve.
  78. Install the shift shaft detent plunger and sleeve.
    Fig 50: Installing Shift Shaft Detent Plunger
    GM661234Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the detent sleeve to 65 N.m (48 lb ft).

  79. If RWD, install the vehicle speed sensor (VSS), with an O-ring seal, in the rear case.
    Fig 51: Installing VSS (RWD)
    GM663712Courtesy of GENERAL MOTORS CORP.
  80. Install the VSS bolt.

    Tighten:  Tighten the VSS bolt to 20 N.m (15 lb ft).

  81. If RWD, install the rear oil seal using the J 44732  . See Special Tools . The seal installer will install the seal at the correct depth.
    Fig 52: Installing Rear Oil Seal (RWD)
    GM724209Courtesy of GENERAL MOTORS CORP.
  82. Lightly lubricate the seal surface with J 36850  or equivalent.
  83. If RWD, install the propeller shaft yoke.
    Fig 53: Installing Propeller Shaft Yoke (RWD)
    GM661231Courtesy of GENERAL MOTORS CORP.
  84. Install a NEW propeller shaft yoke nut.
  85. Install the J 8614-01  in order to hold the transmission shaft from rotating.
    Fig 54: Tightening The Main Shaft Nut (2WD)
    GM727452Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the NEW propeller shaft yoke nut to 330 N.m (244 lb ft).

  86. Install the transmission drain plug and O-ring seal. Ensure the O-ring seal is not damaged.
    Fig 55: Installing Transmission Drain Plug
    GM661219Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the drain plug to 35 N.m (26 lb ft).

  87. If the lower shift lever requires installation before installing in the vehicle, apply a thin layer of gasket maker GM P/N 12378517 (Canadian P/N 88900757) to the sealing surface of the lower shift control lever.
  88. Install the lower shift control lever.
    Fig 56: Installing Shift Control Housing Assembly
    GM661223Courtesy of GENERAL MOTORS CORP.
  89. Install the lower shift control lever bolts.

    Tighten:  Tighten the lower shift control lever bolts to 23 N.m (17 lb ft).

  90. Position the transmission on the transmission bottom.
  91. Install the input shaft seal using the J 44731  .
    Fig 57: Installing Input Shaft Seal
    GM724213Courtesy of GENERAL MOTORS CORP.
  92. Shift the transmission through all of the gears to ensure proper shifting.
  93. Rotate the transmission by the input shaft.

    There should be resistance to turn.

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