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HOMESERVICE MANUALSGMC1995SUBURBAN K2500, 6.5 FREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONMANUAL TRANSMANUAL TRANSMISSION OVERHAUL - NEW VENTURE 4500 5-SPEEDCOMPONENT DISASSEMBLY & REASSEMBLYMAINSHAFT ASSEMBLYREASSEMBLY
1995 GMC Suburban K2500, 6.5 F

MAINSHAFT Assembly: Reassembly

1995 GMC Suburban K2500, 6.5 FSECTION Reassembly
  1. Lubricate bearing assemblies and surfaces with petroleum jelly. Install clutch gear snap ring and 1st gear bearing assembly on rear of mainshaft clutch hub. Install 1st gear with clutch hub side facing front. Install clutch gear on 1st gear and ensure gear is seated on splines.
  2. Install 1st gear snap ring. Ensure snap ring is fully seated in groove. Install reverse synchronizer ring on clutch gear. Ensure synchronizer ring is seated on gear taper. Install reverse gear bearing spacer and reverse gear bearing on mainshaft. See Fig 1.
    Fig 1: Installing Reverse Gear Bearing & Spacer
    G92F14006Courtesy of CHRYSLER CORP.
  3. Install reverse synchronizer sleeve on hub portion of reverse gear and position sleeve taper facing rear. Align teeth on sleeve and hub portion of reverse gear. Install synchronizer springs in hub portion of reverse gear. Slide synchronizer spring back with screwdriver and install synchronizer inserts. Center synchronizer sleeve over inserts.
  4. Install reverse gear synchronizer assembly on mainshaft. Rotate assembly to align hub portion of reverse gear with synchronizer ring lugs and seat reverse gear assembly. Install reverse gear thrust washer locating pin and thrust washer.
  5. Install rear bearing on mainshaft with press. Turn mainshaft over and install 1st clutch gear on mainshaft synchronizer hub, ensuring recessed side of clutch gear faces front. Secure 1st clutch gear with snap ring. Assemble 1st gear synchronizer and clutch ring. Install assembled 1st gear synchronizer and clutch ring on 1st clutch gear.
  6. Assemble 1-2 synchronizer assembly. See Fig 2. Install hub weights in synchronizer hub with retainer springs. Ensure flat spring goes in front side of synchronizer hub. Ensure ends of retainer springs are securely installed in weight slots.
    Fig 2: Identifying 1-2 Synchronizer Components
    G92G14007Courtesy of CHRYSLER CORP.
  7. Align and install 1-2 synchronizer sleeve on hub, ensuring reference marks from disassembly are aligned. Space synchronizer hub off work bench enough to allow synchronizer sleeve to drop down, allowing access to install synchronizer springs and inserts.
  8. Slide 1-2 synchronizer sleeve into Neutral position, ensuring synchronizer inserts are seated and synchronizer springs are not displaced. Install 1st gear synchronizer ring in 1-2 synchronizer hub and sleeve.
  9. Install 1-2 synchronizer assembly on mainshaft. Ensure tapered side of 1-2 synchronizer assembly faces front, and tapered side of reverse synchronizer assembly faces rear.
  10. Remove flat weight spring from front side of 1-2 synchronizer hub to ease installation of 1-2 synchronizer snap ring. Install 1-2 synchronizer snap ring. Reinstall flat weight spring in 1-2 synchronizer hub.
  11. Assemble 2nd clutch gear, clutch ring and synchronizer ring. Install assembly on mainshaft in 1-2 synchronizer hub. Install 2nd clutch gear snap ring, ensuring snap ring is fully seated in groove.
  12. Install 2nd gear bearing and 2nd gear on mainshaft. Install thrust washer locating pin and 2nd gear thrust washer. Install 2nd gear thrust washer snap ring, ensuring snap ring is fully seated in groove.
  13. Install 3rd gear bearing spacer and seat against thrust washer snap ring. Install 3rd gear bearings and 3rd gear. Install synchronizer ring on 3rd gear, ensuring synchronizer ring is fully seated on gear taper.
  14. Assemble 3-4 synchronizer assembly. Install 3-4 synchronizer sleeve on hub, ensuring narrow groove machined on synchronizer hub faces front. Install synchronizer springs in synchronizer hub and sleeve slot of assembly. Slide synchronizer spring back with screwdriver and install synchronizer inserts.
  15. Slide 3-4 synchronizer assembly onto mainshaft, aligning synchronizer ring with sleeve and hub. Ensure grooved side of synchronizer hub faces forward. Drive or press synchronizer assembly remaining distance until seated. Approximately 1/8" of shaft spline is visible when 3-4 synchronizer assembly is seated.
  16. Install 4th synchronizer ring in 3-4 synchronizer sleeve. Install 4th clutch gear in synchronizer ring. Mainshaft assembly is now ready for reassembly into transmission case.
RENDER: 1.0x

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