GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series (Conventional) C4/C5 🢒 Transmission/Transaxle 🢒 Manual Transmission - ZF S6-650 🢒 Shift Shaft and Shift Fork Cleaning and Inspection

    Object Number: 741981 Size: SH
  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.
  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. Object Number: 741982 Size: SH
  10. Inspect the shift shaft forks for wear through the harden surface, scoring, or distortion.
  11. Inspect for a bent shift fork.
  12. Replace the shift forks if damaged or excessively worn.

    13. Object Number: 741984 Size: SH
  13. Inspect the shift shaft detent springs for distortion.
  14. Inspect the internal shift control levers (2 and 4) for wear or damage.
  15. Inspect the shift interlock plate (1) for damage or wear.
    16. • 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. Object Number: 661998 Size: SH

    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.
    22. 21.1. Install the large diameter roll pin.
    21.2. Align the split on the roll pin away from the transmission side of the shift fork.
    21.3. Install the small diameter roll pin inside of the large diameter roll pin.
    21.4. Align the split on the roll pin toward the transmission side of the shift fork.

    Object Number: 662002 Size: SH
  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.
    26. 25.1. Install the large diameter roll pin.
    25.2. Align the split on the roll pin away from the transmission side of the shift fork.
    25.3. Install the small diameter roll pin inside of the large diameter roll pin.
    25.4. Align the split on the roll pin toward the transmission side of the shift fork.

    Object Number: 741981 Size: SH
  1. Clean all the parts in a suitable cleaning solvent. Air dry the parts.
  2. Inspect the shift shafts for being bent. Roll on a flat surface.
  3. Inspect the shift shafts for wear or scoring.
  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 excessive wear.

    10. Object Number: 741982 Size: SH
  10. Inspect the shift shaft forks for wear through the harden surface, scoring, or distortion.
  11. Inspect for bent shift fork.
  12. Replace the shift forks if damaged or excessive wear.

    13. Object Number: 741984 Size: SH
  13. Inspect the shift shaft detent springs for distortion.
  14. Inspect the internal shift control levers (2 and 4) for wear or damage.
  15. Inspect the shift interlock plate (1) for damage or wear.
    16. • Inspect shift block teeth area
    • Inspect mounting bolt slots
    • Inspect for bent or warpage
  16. Inspect the shift shaft block (3) for excessive worn teeth.
  17. Replace any damaged or excessive worn parts.

    18. Object Number: 661998 Size: SH

    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.
    22. 21.1. Install the large diameter roll pin.
    21.2. Align the split on the roll pin away from the transmission side of the shift fork.
    21.3. Install the small diameter roll pin inside of the large diameter roll pin.
    21.4. Align the split on the roll pin towards the transmission side of the shift fork.

    Object Number: 662002 Size: SH
  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.
    26. 25.1. Install the large diameter roll pin.
    25.2. Align the split on the roll pin away from the transmission side of the shift fork.
    25.3. Install the small diameter roll pin inside of the large diameter roll pin.
    25.4. Align the split on the roll pin towards the transmission side of the shift fork.