Service Procedure

Remove the transmission from the vehicle following directions in the appropriate service manual, Section 7B, Manual Transmission, Transmission Replacement. Refer to the 1994 Light Duty Truck Unit Repair Manual (Section 7B1, New Venture Gear 3500 Manual Transmission) for unit disassembly and assembly. Follow the procedures listed to:

1. Remove the front and rear housings.

2. Remove and do not reuse the following parts:

- 5th/reverse shift fork (# 100)

- shift shaft bushing (# 103)

- shift shaft lever (# 104)

- shift shaft (# 108)

- bias spring (# 109)

- anti-rotation bracket (# 111)

- detent plunger spring (# 244)

3. Install the following revised parts:

- 5th/reverse shift fork (# 100)

- shift shaft bushing (# 103)

- shift shaft (# 108)

- shift shaft lever (# 104)

- detent spring (# 106)

- detent plunger (# 107)

- detent plunger spring (# 244)

4. Install the front and rear housings.

5. Install a revised shift lever insulator under the shift boot (S/T only).

Important:
When Installing a "self-biasing" shift tower the bias spring (# 109) and anti-rotation bracket (# 110) must be removed from the transmission. A revised 5th/reverse shift fork (# 100), revised shift shaft bushing (# 103) and detent plunger spring (# 244) must also be installed.

The following parts are NOT reusable and must be replaced every time they are removed:

^ Input shaft snap ring (# 210)

^ Main shaft snap ring (K only) (# 43)

^ Retaining pins (# 105, # 113)





The fastener tightening specifications should be used:

The following sealants should be used for reassembly:

P/N 1052942 Anaerobic Sealant

- Shift cover-to-case

- Front-to-rear housing

- Input bearing retainer P/N 12346004 Pipe Sealant with TEFLON:

- Drain and fill plugs

- Shift shaft detent plug





SERVICE PARTS INFORMATION:

RPO Definitions: NPI - Electric Shift Transfer Case

Parts are currently available from GMSPO.

WARRANTY INFORMATION:
For vehicles repaired under warranty, use:

Labor Description Labor Time
Operation

K2767 5th Fork, and/or Use Published
Shaft, Replace Labor Operation
Time





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